Smart sensors with local signal processing

ABSTRACT

A device including smart sensors with a local signal processor is disclosed. The device includes an end-effector including at least one sensor and a signal processing component corresponding to the at least one sensor; and a handle configured to receive processed information from the signal processing component. The processed information is generated by the signal processing component at the end-effector based on data received from the at least one sensor at the end-effector.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/005,241, entitledSMART SENSORS WITH LOCAL SIGNAL PROCESSING, filed Jun. 11, 2018, nowU.S. Patent Application Publication No. 2018/0289369, which is adivisional application claiming priority under 35 U.S.C. § 121 to U.S.patent application Ser. No. 14/640,837, entitled SMART SENSORS WITHLOCAL SIGNAL PROCESSING, filed Mar. 6, 2015, which issued on Jun. 12,2018 as U.S. Pat. No. 9,993,248, the entire disclosures of which arehereby incorporated by reference herein.

BACKGROUND

The present disclosure relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present disclosure, and the manner ofattaining them, will become more apparent and the present disclosurewill be better understood by reference to the following description ofthe present disclosure taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaftassembly and surgical instrument of FIG. 1;

FIG. 3 is another exploded assembly view showing portions of theinterchangeable shaft assembly and surgical instrument of FIGS. 1 and 2;

FIG. 4 is an exploded assembly view of a portion of the surgicalinstrument of FIGS. 1-3;

FIG. 5 is a cross-sectional side view of a portion of the surgicalinstrument of FIG. 4 with the firing trigger in a fully actuatedposition;

FIG. 6 is another cross-sectional view of a portion of the surgicalinstrument of FIG. 5 with the firing trigger in an unactuated position;

FIG. 7 is an exploded assembly view of one form of an interchangeableshaft assembly;

FIG. 8 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIG. 7;

FIG. 9 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIGS. 7 and 8;

FIG. 10 is a cross-sectional view of a portion of the interchangeableshaft assembly of FIGS. 7-9;

FIG. 11 is a perspective view of a portion of the shaft assembly ofFIGS. 7-10 with the switch drum omitted for clarity;

FIG. 12 is another perspective view of the portion of theinterchangeable shaft assembly of FIG. 11 with the switch drum mountedthereon;

FIG. 13 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anunactuated position;

FIG. 14 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 13;

FIG. 15 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 13 and 14;

FIG. 16 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and a firing trigger thereof in an unactuatedposition;

FIG. 17 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 16;

FIG. 18 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 16 and 17;

FIG. 18A is a right side elevational view of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and the firing trigger thereof in an actuatedposition;

FIG. 19 is a schematic of a system for powering down an electricalconnector of a surgical instrument handle when a shaft assembly is notcoupled thereto;

FIG. 20 is an exploded view of one aspect of an end effector of thesurgical instrument of FIG. 1;

FIGS. 21A-21B is a circuit diagram of the surgical instrument of FIG. 1spanning two drawings sheets;

FIG. 22 illustrates one instance of a power assembly comprising a usagecycle circuit configured to generate a usage cycle count of the batteryback;

FIG. 23 illustrates one aspect of a process for sequentially energizinga segmented circuit;

FIG. 24 illustrates one aspect of a power segment comprising a pluralityof daisy chained power converters;

FIG. 25 illustrates one aspect of a segmented circuit configured tomaximize power available for critical and/or power intense functions;

FIG. 26 illustrates one aspect of a power system comprising a pluralityof daisy chained power converters configured to be sequentiallyenergized;

FIG. 27 illustrates one aspect of a segmented circuit comprising anisolated control section;

FIG. 28, which is divided into FIGS. 28A and 28B, is a circuit diagramof the surgical instrument of FIG. 1;

FIG. 29 is a block diagram the surgical instrument of FIG. 1illustrating interfaces between the handle assembly 14 and the powerassembly and between the handle assembly 14 and the interchangeableshaft assembly;

FIG. 30 depicts an example medical device that can include one or moreaspects of the present disclosure;

FIG. 31 depicts an example end-effector of a medical device that caninclude one or more aspects of the present disclosure;

FIG. 32 also depicts an example end-effector of a medical device thatcan include one or more aspects of the present disclosure;

FIG. 33 is a diagram of a smart sensor component in accordance with anaspect the present disclosure;

FIG. 34 is a logic diagram illustrating one aspect of a process forcalibrating a first sensor in response to an input from a second sensor;

FIG. 35 is a logic diagram illustrating one aspect of a process foradjusting a measurement of a first sensor in response to a plurality ofsecondary sensors;

FIG. 36 illustrates one aspect of a circuit configured to convertsignals from a first sensor and a plurality of secondary sensors intodigital signals receivable by a processor;

FIG. 37 is a logic diagram illustrating one aspect of a process forselecting the most reliable output from a plurality of redundantsensors;

FIG. 38 illustrates a sideways cross-sectional view of one aspect of anend effector comprising a magnet and a magnetic field sensor incommunication with processor;

FIGS. 39-41 illustrate one aspect of an end effector that comprises amagnet where FIG. 39 illustrates a perspective cutaway view of the anviland the magnet, FIG. 40 illustrates a side cutaway view of the anvil andthe magnet, and FIG. 41 illustrates a top cutaway view of the anvil andthe magnet;

FIG. 42 illustrates one aspect of an end effector that is operable touse conductive surfaces at the distal contact point to create anelectrical connection;

FIG. 43 illustrates one aspect of an exploded view of a staple cartridgethat comprises a flex cable connected to a magnetic field sensor andprocessor;

FIG. 44 illustrates the end effector shown in FIG. 43 with a flex cableand without the shaft assembly;

FIGS. 45 and 46 illustrate an elongated channel portion of an endeffector without the anvil or the staple cartridge, to illustrate howthe flex cable shown in FIG. 44 can be seated within the elongatedchannel;

FIG. 47 illustrates a flex cable, shown in FIGS. 44-46, alone;

FIG. 48 illustrates a close up view of the elongated channel shown inFIGS. 45 and 46 with a staple cartridge coupled thereto;

FIGS. 49 and 50 illustrate one aspect of a distal sensor plug where FIG.49 illustrates a cutaway view of the distal sensor plug and FIG. 50further illustrates the magnetic field sensor and the processoroperatively coupled to the flex board such that they are capable ofcommunicating;

FIG. 51 illustrates an aspect of an end effector with a flex cableoperable to provide power to sensors and electronics in the distal tipof the anvil portion;

FIGS. 52-54 illustrate the operation of the articulation joint and flexcable of the end effector where FIG. 52 illustrates a top view of theend effector with the end effector pivoted −45 degrees with respect tothe shaft assembly, FIG. 53 illustrates a top view of the end effector,and FIG. 54 illustrates a top view of the end effector with the endeffector pivoted +45 degrees with respect to the shaft assembly;

FIG. 55 illustrates cross-sectional view of the distal tip of an aspectof an anvil with sensors and electronics; and

FIG. 56 illustrates a cutaway view of the distal tip of the anvil.

DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/640,746, entitled POWERED SURGICALINSTRUMENT; now U.S. Pat. No. 9,808,246;

U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE LEVELTHRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS; now U.S.Patent Application Publication No. 2016/0256185;

U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE TISSUECOMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUETYPES; now U.S. Patent Application Publication No. 2016/0256154;

U.S. patent application Ser. No. 14/640,935, entitled OVERLAID MULTISENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUECOMPRESSION; now U.S. Patent Application Publication No. 2016/0256071;

U.S. patent application Ser. No. 14/640,831, entitled MONITORING SPEEDCONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICALINSTRUMENTS; now U.S. Pat. No. 9,895,148;

U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENTEVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, ANDVISCOELASTIC ELEMENTS OF MEASURES; now U.S. Pat. No. 10,052,044;

U.S. patent application Ser. No. 14/640,817, entitled INTERACTIVEFEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS; now U.S. Pat. No.9,924,961;

U.S. patent application Ser. No. 14/640,844, entitled CONTROL TECHNIQUESAND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROLPROCESSING FROM HANDLE; now U.S. Pat. No. 10,045,776;

U.S. patent application Ser. No. 14/640,780, entitled SURGICALINSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING; now U.S. Pat. No.10,245,033;

U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FORDETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICALSTAPLER; now U.S. Patent Application Publication No. 2016/0256160; and

U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND POWERCOMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT; now U.S. Pat. No.9,901,342.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/633,576, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION; now U.S. Pat. No.10,045,779;

U.S. patent application Ser. No. 14/633,546, entitled SURGICAL APPARATUSCONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICALAPPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND; now U.S. Pat. No.10,180,463;

U.S. patent application Ser. No. 14/633,560, entitled SURGICAL CHARGINGSYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES; now U.S.Patent Application Publication No. 2016/0249910;

U.S. patent application Ser. No. 14/633,566, entitled CHARGING SYSTEMTHAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY; now U.S. Pat.No. 10,182,816;

U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FORMONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED; now U.S.Pat. No. 10,321,907;

U.S. patent application Ser. No. 14/633,542, entitled REINFORCED BATTERYFORA SURGICAL INSTRUMENT; now U.S. Pat. No. 9,931,118;

U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER FORA SURGICAL INSTRUMENT; now U.S. Pat. No. 10,245,028;

U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE SURGICALINSTRUMENT HANDLE; now U.S. Pat. No. 9,993,258;

U.S. patent application Ser. No. 14/633,541, entitled MODULAR STAPLINGASSEMBLY; now U.S. Pat. No. 10,226,250; and

U.S. patent application Ser. No. 14/633,562, entitled SURGICAL APPARATUSCONFIGURED TO TRACK AN END-OF-LIFE PARAMETER; now U.S. Pat. No.10,159,483.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/574,478, entitled SURGICALINSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANSFOR ADJUSTING THE FIRING STROKE OF A FIRING; now U.S. Pat. No.9,844,374;

U.S. patent application Ser. No. 14/574,483, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS; now U.S. Pat. No.10,188,385;

U.S. patent application Ser. No. 14/575,139, entitled DRIVE ARRANGEMENTSFOR ARTICULATABLE SURGICAL INSTRUMENTS; now U.S. Pat. No. 9,844,375;

U.S. patent application Ser. No. 14/575,148, entitled LOCKINGARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICALEND EFFECTORS; now U.S. Pat. No. 10,085,748;

U.S. patent application Ser. No. 14/575,130, entitled SURGICALINSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETENON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE; now U.S. Pat. No.10,245,027;

U.S. patent application Ser. No. 14/575,143, entitled SURGICALINSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS; now U.S. Pat. No.10,004,501;

U.S. patent application Ser. No. 14/575,117, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAMSUPPORT ARRANGEMENTS; now U.S. Pat. No. 9,943,309;

U.S. patent application Ser. No. 14/575,154, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING BEAMSUPPORT ARRANGEMENTS; now U.S. Pat. No. 9,968,355;

U.S. patent application Ser. No. 14/574,493, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM; now U.S.Pat. No. 9,987,000; and

U.S. patent application Ser. No. 14/574,500, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM; now U.S.Pat. No. 10,117,649.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent appliation Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION;now U.S. Pat. No. 9,700,309;

U.S. patent appliation Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS; now U.S. Pat. No.9,782,169;

U.S. patent appliation Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS; now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent appliation Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT; now U.S. Pat. No.9,358,003;

U.S. patent appliation Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS; now U.S. Pat. No.9,554,794;

U.S. patent appliation Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS; now U.S. Pat. No. 9,326,767;

U.S. patent appliation Ser. No. 13/782,481, entitled SENSOR STRAIGHTENEDEND EFFECTOR DURING REMOVAL THROUGH TROCAR; now U.S. Pat. No. 9,468,438;

U.S. patent appliation Ser. No. 13/782,518, entitled CONTROL METHODS FORSURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS; now U.S. PatentApplication Publication No. 2014/0246475;

U.S. patent appliation Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM; now U.S. Pat. No.9,398,911; and

U.S. patent appliation Ser. No. 13/782,536, entitled SURGICAL INSTRUMENTSOFT STOP; now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent appliation Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE; now U.S. Pat. No.9,687,230;

U.S. patent appliation Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT; now U.S. Pat.No. 9,332,987;

U.S. patent appliation Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT; now U.S. Pat. No.9,883,860;

U.S. patent appliation Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK; now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent appliation Ser. No. 13/803,210, entitled SENSOR ARRANGEMENTSFOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS; now U.S. Pat.No. 9,808,244;

U.S. patent appliation Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT; now U.S. Patent Application PublicationNo. 2014/0263554;

U.S. patent appliation Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS; now U.S. Pat. No.9,629,623;

U.S. patent appliation Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS; now U.S. Pat. No.9,351,726;

U.S. patent appliation Ser. No. 13/803,130, entitled DRIVE TRAIN CONTROLARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS; now U.S. Pat. No.9,351,727; and

U.S. patent appliation Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT; now U.S. Pat. No. 9,888,919.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

U.S. patent application Ser. No. 14/200,111, entitled CONTROL SYSTEMSFOR SURGICAL INSTRUMENTS; now U.S. Pat. No. 9,629,629.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS; now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT; now U.S. Pat. No. 9,826,977;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OFNUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT; now U.S. Patent ApplicationPublication No. 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL; now U.S.Pat. No. 10,013,049;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES; now U.S. Pat. No.9,743,929;

U.S. patent application Ser. No. 14/226,093, entitled FEEDBACKALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS; now U.S.Pat. No. 10,028,761;

U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION; now U.S. Patent ApplicationPublication No. 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled SURGICALINSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR; now U.S. Pat. No.9,690,362;

U.S. patent application Ser. No. 14/226,097, entitled SURGICALINSTRUMENT COMPRISING INTERACTIVE SYSTEMS; now U.S. Pat. No. 9,820,738;

U.S. patent application Ser. No. 14/226,126, entitled INTERFACE SYSTEMSFOR USE WITH SURGICAL INSTRUMENTS; now U.S. Pat. No. 10,004,497;

U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM; now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT; now U.S. Pat. No.9,804,618;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION; now U.S. Pat.No. 9,733,663;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM; now U.S. Pat. No. 9,750,499; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT; now U.S. Pat. No. 10,201,364.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY ANDSENSORS FOR POWERED MEDICAL DEVICE; now U.S. Pat. No. 10,111,679;

U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITHINTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION; now U.S. Pat. No.9,724,094;

U.S. patent application Ser. No. 14/478,908, entitled MONITORING DEVICEDEGRADATION BASED ON COMPONENT EVALUATION; now U.S. Pat. No. 9,737,301;

U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE SENSORSWITH ONE SENSOR AFFECTING A SECOND SENSOR′S OUTPUT OR INTERPRETATION;now U.S. Pat. No. 9,757,128;

U.S. patent application Ser. No. 14/479,110, entitled USE OF POLARITY OFHALL MAGNET DETECTION TO DETECT MISLOADED CARTRIDGE; now U.S. Pat. No.10,016,199;

U.S. patent application Ser. No. 14/479,098, entitled SMART CARTRIDGEWAKE UP OPERATION AND DATA RETENTION; now U.S. Pat. No. 10,135,242;

U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTORCONTROL FOR POWERED MEDICAL DEVICE; now U.S. Pat. No. 9,788,836; and

U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY OFTISSUE PARAMETER STABILIZATION; now U.S. Patent Application PublicationNo. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS; now U.S. Pat. No.9,826,976;

U.S. patent application Ser. No. 14/248,581, entitled SURGICALINSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROMTHE SAME ROTATABLE OUTPUT; now U.S. Pat. No. 9,649,110;

U.S. patent application Ser. No. 14/248,595, entitled SURGICALINSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THESURGICAL INSTRUMENT; now U.S. Pat. No. 9,844,368;

U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEARSURGICAL STAPLER; now U.S. Pat. No. 10,405,857;

U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSIONARRANGEMENT FOR A SURGICAL INSTRUMENT; now U.S. Pat. No. 10,149,680;

U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARYDRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS; now U.S. Pat. No.9,801,626;

U.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER; now U.S. Pat. No. 9,867,612;

U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEMDECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT; now U.S. Pat. No.10,136,887; and

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS; nowU.S. Pat. No. 9,814,460.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. Provisional Patent Application Ser. No. 61/812,365, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR;

U.S. Provisional Patent Application Ser. No. 61/812,376, entitled LINEARCUTTER WITH POWER;

U.S. Provisional Patent Application Ser. No. 61/812,382, entitled LINEARCUTTER WITH MOTOR AND PISTOL GRIP;

U.S. Provisional Patent Application Ser. No. 61/812,385, entitledSURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTORCONTROL; and

U.S. Provisional Patent Application Ser. No. 61/812,372, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR.

The present disclosure provides an overall understanding of theprinciples of the structure, function, manufacture, and use of thedevices and methods disclosed herein. One or more examples of theseaspects are illustrated in the accompanying drawings. Those of ordinaryskill in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting examples. The features illustrated ordescribed in connection with one example may be combined with thefeatures of other examples. Such modifications and variations areintended to be included within the scope of the present disclosure.

Reference throughout the specification to “various aspects,” “someaspects,” “one aspect,” or “an aspect”, or the like, means that aparticular feature, structure, or characteristic described in connectionwith the aspect is included in at least one aspect. Thus, appearances ofthe phrases “in various aspects,” “in some aspects,” “in one aspect”, or“in an aspect”, or the like, in places throughout the specification arenot necessarily all referring to the same aspect. Furthermore, theparticular features, structures, or characteristics may be combined inany suitable manner in one or more aspects. Thus, the particularfeatures, structures, or characteristics illustrated or described inconnection with one aspect may be combined, in whole or in part, withthe features structures, or characteristics of one or more other aspectswithout limitation. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical,” “horizontal,” “up,” and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various example devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIGS. 1-6 depict a motor-driven surgical cutting and fasteninginstrument 10 that may or may not be reused. In the illustratedexamples, the instrument 10 includes a housing 12 that comprises ahandle assembly 14 that is configured to be grasped, manipulated andactuated by the clinician. The housing 12 is configured for operableattachment to an interchangeable shaft assembly 200 that has a surgicalend effector 300 operably coupled thereto that is configured to performone or more surgical tasks or procedures. As the present DetailedDescription proceeds, it will be understood that the various unique andnovel arrangements of the various forms of interchangeable shaftassemblies disclosed herein also may be effectively employed inconnection with robotically-controlled surgical systems. Thus, the term“housing” also may encompass a housing or similar portion of a roboticsystem that houses or otherwise operably supports at least one drivesystem that is configured to generate and apply at least one controlmotion which could be used to actuate the interchangeable shaftassemblies disclosed herein and their respective equivalents. The term“frame” may refer to a portion of a handheld surgical instrument. Theterm “frame” also may represent a portion of a robotically controlledsurgical instrument and/or a portion of the robotic system that may beused to operably control a surgical instrument. For example, theinterchangeable shaft assemblies disclosed herein may be employed withvarious robotic systems, instruments, components and methods disclosedin U.S. patent application Ser. No. 13/118,241, entitled SURGICALSTAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, nowU.S. Pat. No. 9,072,535. U.S. patent appliation Ser. No. 13/118,241,entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, is incorporated by referenceherein in its entirety.

The housing 12 depicted in FIGS. 1-3 is shown in connection with aninterchangeable shaft assembly 200 that includes an end effector 300that comprises a surgical cutting and fastening device that isconfigured to operably support a surgical staple cartridge 304 therein.The housing 12 may be configured for use in connection withinterchangeable shaft assemblies that include end effectors that areadapted to support different sizes and types of staple cartridges, havedifferent shaft lengths, sizes, and types, etc. In addition, the housing12 also may be effectively employed with a variety of otherinterchangeable shaft assemblies including those assemblies that areconfigured to apply other motions and forms of energy such as, forexample, radio frequency (RF) energy, ultrasonic energy and/or motion toend effector arrangements adapted for use in connection with varioussurgical applications and procedures. Furthermore, the end effectors,shaft assemblies, handles, surgical instruments, and/or surgicalinstrument systems can utilize any suitable fastener, or fasteners, tofasten tissue. For instance, a fastener cartridge comprising a pluralityof fasteners removably stored therein can be removably inserted intoand/or attached to the end effector of a shaft assembly.

FIG. 1 illustrates the surgical instrument 10 with an interchangeableshaft assembly 200 operably coupled thereto. FIGS. 2 and 3 illustrateattachment of the interchangeable shaft assembly 200 to the housing 12or handle assembly 14. As shown in FIG. 4, the handle assembly 14 maycomprise a pair of interconnectable handle housing segments 16 and 18that may be interconnected by screws, snap features, adhesive, etc. Inthe illustrated arrangement, the handle housing segments 16, 18cooperate to form a pistol grip portion 19 that can be gripped andmanipulated by the clinician. As will be discussed in further detailbelow, the handle assembly 14 operably supports a plurality of drivesystems therein that are configured to generate and apply variouscontrol motions to corresponding portions of the interchangeable shaftassembly that is operably attached thereto.

Referring now to FIG. 4, the handle assembly 14 may further include aframe 20 that operably supports a plurality of drive systems. Forexample, the frame 20 can operably support a “first” or closure drivesystem, generally designated as 30, which may be employed to applyclosing and opening motions to the interchangeable shaft assembly 200that is operably attached or coupled thereto. In at least one form, theclosure drive system 30 may include an actuator in the form of a closuretrigger 32 that is pivotally supported by the frame 20. Morespecifically, as illustrated in FIG. 4, the closure trigger 32 ispivotally coupled to the housing 14 by a pin 33. Such arrangementenables the closure trigger 32 to be manipulated by a clinician suchthat when the clinician grips the pistol grip portion 19 of the handleassembly 14, the closure trigger 32 may be easily pivoted from astarting or “unactuated” position to an “actuated” position and moreparticularly to a fully compressed or fully actuated position. Theclosure trigger 32 may be biased into the unactuated position by springor other biasing arrangement (not shown). In various forms, the closuredrive system 30 further includes a closure linkage assembly 34 that ispivotally coupled to the closure trigger 32. As shown in FIG. 4, theclosure linkage assembly 34 may include a first closure link 36 and asecond closure link 38 that are pivotally coupled to the closure trigger32 by a pin 35. The second closure link 38 also may be referred toherein as an “attachment member” and include a transverse attachment pin37.

Still referring to FIG. 4, it can be observed that the first closurelink 36 may have a locking wall or end 39 thereon that is configured tocooperate with a closure release assembly 60 that is pivotally coupledto the frame 20. In at least one form, the closure release assembly 60may comprise a release button assembly 62 that has a distally protrudinglocking pawl 64 formed thereon. The release button assembly 62 may bepivoted in a counterclockwise direction by a release spring (not shown).As the clinician depresses the closure trigger 32 from its unactuatedposition towards the pistol grip portion 19 of the handle assembly 14,the first closure link 36 pivots upward to a point wherein the lockingpawl 64 drops into retaining engagement with the locking wall 39 on thefirst closure link 36 thereby preventing the closure trigger 32 fromreturning to the unactuated position. See FIG. 18. Thus, the closurerelease assembly 60 serves to lock the closure trigger 32 in the fullyactuated position. When the clinician desires to unlock the closuretrigger 32 to permit it to be biased to the unactuated position, theclinician simply pivots the closure release button assembly 62 such thatthe locking pawl 64 is moved out of engagement with the locking wall 39on the first closure link 36. When the locking pawl 64 has been movedout of engagement with the first closure link 36, the closure trigger 32may pivot back to the unactuated position. Other closure trigger lockingand release arrangements also may be employed.

Further to the above, FIGS. 13-15 illustrate the closure trigger 32 inits unactuated position which is associated with an open, or unclamped,configuration of the shaft assembly 200 in which tissue can bepositioned between the jaws of the shaft assembly 200. FIGS. 16-18illustrate the closure trigger 32 in its actuated position which isassociated with a closed, or clamped, configuration of the shaftassembly 200 in which tissue is clamped between the jaws of the shaftassembly 200. Upon comparing FIGS. 14 and 17, the reader will appreciatethat, when the closure trigger 32 is moved from its unactuated position(FIG. 14) to its actuated position (FIG. 17), the closure release button62 is pivoted between a first position (FIG. 14) and a second position(FIG. 17). The rotation of the closure release button 62 can be referredto as being an upward rotation; however, at least a portion of theclosure release button 62 is being rotated toward the circuit board 100.Referring to FIG. 4, the closure release button 62 can include an arm 61extending therefrom and a magnetic element 63, such as a permanentmagnet, for example, mounted to the arm 61. When the closure releasebutton 62 is rotated from its first position to its second position, themagnetic element 63 can move toward the circuit board 100. The circuitboard 100 can include at least one sensor configured to detect themovement of the magnetic element 63. In at least one aspect, a magneticfield sensor 65, for example, can be mounted to the bottom surface ofthe circuit board 100. The magnetic field sensor 65 can be configured todetect changes in a magnetic field surrounding the magnetic field sensor65 caused by the movement of the magnetic element 63. The magnetic fieldsensor 65 can be in signal communication with a microcontroller 1500(FIG. 19), for example, which can determine whether the closure releasebutton 62 is in its first position, which is associated with theunactuated position of the closure trigger 32 and the open configurationof the end effector, its second position, which is associated with theactuated position of the closure trigger 32 and the closed configurationof the end effector, and/or any position between the first position andthe second position.

As used throughout the present disclosure, a magnetic field sensor maybe a Hall effect sensor, search coil, fluxgate, optically pumped,nuclear precession, SQUID, Hall-effect, anisotropic magnetoresistance,giant magnetoresistance, magnetic tunnel junctions, giantmagnetoimpedance, magnetostrictive/piezoelectric composites,magnetodiode, magnetotransistor, fiber optic, magnetooptic, andmicroelectromechanical systems-based magnetic sensors, among others.

In at least one form, the handle assembly 14 and the frame 20 mayoperably support another drive system referred to herein as a firingdrive system 80 that is configured to apply firing motions tocorresponding portions of the interchangeable shaft assembly attachedthereto. The firing drive system may 80 also be referred to herein as a“second drive system”. The firing drive system 80 may employ an electricmotor 82, located in the pistol grip portion 19 of the handle assembly14. In various forms, the motor 82 may be a DC brushed driving motorhaving a maximum rotation of, approximately, 25,000 RPM, for example. Inother arrangements, the motor may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. The motor 82 may be powered by a power source 90 that inone form may comprise a removable power pack 92. As shown in FIG. 4, forexample, the power pack 92 may comprise a proximal housing portion 94that is configured for attachment to a distal housing portion 96. Theproximal housing portion 94 and the distal housing portion 96 areconfigured to operably support a plurality of batteries 98 therein.Batteries 98 may each comprise, for example, a Lithium Ion (“LI”) orother suitable battery. The distal housing portion 96 is configured forremovable operable attachment to a control circuit board assembly 100which is also operably coupled to the motor 82. A number of batteries 98may be connected in series may be used as the power source for thesurgical instrument 10. In addition, the power source 90 may bereplaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 82 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 84 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 122 on alongitudinally-movable drive member 120. In use, a voltage polarityprovided by the power source 90 can operate the electric motor 82 in aclockwise direction wherein the voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor 82 in a counter-clockwise direction. When the electric motor 82 isrotated in one direction, the drive member 120 will be axially driven inthe distal direction “DD”. When the motor 82 is driven in the oppositerotary direction, the drive member 120 will be axially driven in aproximal direction “PD”. The handle assembly 14 can include a switchwhich can be configured to reverse the polarity applied to the electricmotor 82 by the power source 90. As with the other forms describedherein, the handle assembly 14 can also include a sensor that isconfigured to detect the position of the drive member 120 and/or thedirection in which the drive member 120 is being moved.

Actuation of the motor 82 can be controlled by a firing trigger 130 thatis pivotally supported on the handle assembly 14. The firing trigger 130may be pivoted between an unactuated position and an actuated position.The firing trigger 130 may be biased into the unactuated position by aspring 132 or other biasing arrangement such that when the clinicianreleases the firing trigger 130, it may be pivoted or otherwise returnedto the unactuated position by the spring 132 or biasing arrangement. Inat least one form, the firing trigger 130 can be positioned “outboard”of the closure trigger 32 as was discussed above. In at least one form,a firing trigger safety button 134 may be pivotally mounted to theclosure trigger 32 by pin 35. The safety button 134 may be positionedbetween the firing trigger 130 and the closure trigger 32 and have apivot arm 136 protruding therefrom. See FIG. 4. When the closure trigger32 is in the unactuated position, the safety button 134 is contained inthe handle assembly 14 where the clinician cannot readily access it andmove it between a safety position preventing actuation of the firingtrigger 130 and a firing position wherein the firing trigger 130 may befired. As the clinician depresses the closure trigger 32, the safetybutton 134 and the firing trigger 130 pivot down wherein they can thenbe manipulated by the clinician.

As discussed above, the handle assembly 14 can include a closure trigger32 and a firing trigger 130. Referring to FIGS. 14-18A, the firingtrigger 130 can be pivotably mounted to the closure trigger 32. Theclosure trigger 32 can include an arm 31 extending therefrom and thefiring trigger 130 can be pivotably mounted to the arm 31 about a pivotpin 33. When the closure trigger 32 is moved from its unactuatedposition (FIG. 14) to its actuated position (FIG. 17), the firingtrigger 130 can descend downwardly, as outlined above. After the safetybutton 134 has been moved to its firing position, referring primarily toFIG. 18A, the firing trigger 130 can be depressed to operate the motorof the surgical instrument firing system. In various instances, thehandle assembly 14 can include a tracking system, such as system 800,for example, configured to determine the position of the closure trigger32 and/or the position of the firing trigger 130. With primary referenceto FIGS. 14, 17, and 18A, the tracking system 800 can include a magneticelement, such as permanent magnet 802, for example, which is mounted toan arm 801 extending from the firing trigger 130. The tracking system800 can comprise one or more sensors, such as a first magnetic fieldsensor 803 and a second magnetic field sensor 804, for example, whichcan be configured to track the position of the magnet 802.

Upon comparing FIGS. 14 and 17, the reader will appreciate that, whenthe closure trigger 32 is moved from its unactuated position to itsactuated position, the magnet 802 can move between a first positionadjacent the first magnetic field sensor 803 and a second positionadjacent the second magnetic field sensor 804.

Upon comparing FIGS. 17 and 18A, the reader will further appreciatethat, when the firing trigger 130 is moved from an unfired position(FIG. 17) to a fired position (FIG. 18A), the magnet 802 can moverelative to the second magnetic field sensor 804. The sensors 803 and804 can track the movement of the magnet 802 and can be in signalcommunication with a microcontroller on the circuit board 100. With datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the closure trigger 32 is in its unactuated position,its actuated position, or a position therebetween. Similarly, with datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the firing trigger 130 is in its unfired position, itsfully fired position, or a position therebetween.

As indicated above, in at least one form, the longitudinally movabledrive member 120 has a rack of teeth 122 formed thereon for meshingengagement with a corresponding drive gear 86 of the gear reducerassembly 84. At least one form also includes a manually-actuatable“bailout” assembly 140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 120 should themotor 82 become disabled. The bailout assembly 140 may include a leveror bailout handle assembly 14 that is configured to be manually pivotedinto ratcheting engagement with teeth 124 also provided in the drivemember 120. Thus, the clinician can manually retract the drive member120 by using the bailout handle assembly 14 to ratchet the drive member120 in the proximal direction “PD”. U.S. Patent Application PublicationNo. 2010/0089970, now U.S. Pat. No. 8,608,045 discloses bailoutarrangements and other components, arrangements and systems that alsomay be employed with the various instruments disclosed herein. U.S.patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045, is hereby incorporated by reference in itsentirety.

Turning now to FIGS. 1 and 7, the interchangeable shaft assembly 200includes a surgical end effector 300 that comprises an elongated channel302 that is configured to operably support a staple cartridge 304therein. The end effector 300 may further include an anvil 306 that ispivotally supported relative to the elongated channel 302. Theinterchangeable shaft assembly 200 may further include an articulationjoint 270 and an articulation lock 350 (FIG. 8) which can be configuredto releasably hold the end effector 300 in a desired position relativeto a shaft axis SA-SA. Details regarding the construction and operationof the end effector 300, the articulation joint 270 and the articulationlock 350 are set forth in U.S. patent application Ser. No. 13/803,086,filed Mar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENTCOMPRISING AN ARTICULATION LOCK, now U.S. Patent Application PublicationNo. 2014/0263541. The entire disclosure of U.S. patent appliation Ser.No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. Patent ApplicationPublication No. 2014/0263541, is hereby incorporated by referenceherein. As shown in FIGS. 7 and 8, the interchangeable shaft assembly200 can further include a proximal housing or nozzle 201 comprised ofnozzle portions 202 and 203. The interchangeable shaft assembly 200 canfurther include a closure tube 260 which can be utilized to close and/oropen the anvil 306 of the end effector 300. Primarily referring now toFIGS. 8 and 9, the shaft assembly 200 can include a spine 210 which canbe configured to fixably support a shaft frame portion 212 of thearticulation lock 350. See FIG. 8. The spine 210 can be configured to,one, slidably support a firing member 220 therein and, two, slidablysupport the closure tube 260 which extends around the spine 210. Thespine 210 can also be configured to slidably support a proximalarticulation driver 230. The articulation driver 230 has a distal end231 that is configured to operably engage the articulation lock 350. Thearticulation lock 350 interfaces with an articulation frame 352 that isadapted to operably engage a drive pin (not shown) on the end effectorframe (not shown). As indicated above, further details regarding theoperation of the articulation lock 350 and the articulation frame may befound in U.S. patent appliation Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541. In various circumstances, thespine 210 can comprise a proximal end 211 which is rotatably supportedin a chassis 240. In one arrangement, for example, the proximal end 211of the spine 210 has a thread 214 formed thereon for threaded attachmentto a spine bearing 216 configured to be supported within the chassis240. See FIG. 7. Such an arrangement facilitates rotatable attachment ofthe spine 210 to the chassis 240 such that the spine 210 may beselectively rotated about a shaft axis SA-SA relative to the chassis240.

Referring primarily to FIG. 7, the interchangeable shaft assembly 200includes a closure shuttle 250 that is slidably supported within thechassis 240 such that it may be axially moved relative thereto. As shownin FIGS. 3 and 7, the closure shuttle 250 includes a pair ofproximally-protruding hooks 252 that are configured for attachment tothe attachment pin 37 that is attached to the second closure link 38 aswill be discussed in further detail below. A proximal end 261 of theclosure tube 260 is coupled to the closure shuttle 250 for relativerotation thereto. For example, a U shaped connector 263 is inserted intoan annular slot 262 in the proximal end 261 of the closure tube 260 andis retained within vertical slots 253 in the closure shuttle 250. SeeFIG. 7. Such an arrangement serves to attach the closure tube 260 to theclosure shuttle 250 for axial travel therewith while enabling theclosure tube 260 to rotate relative to the closure shuttle 250 about theshaft axis SA-SA. A closure spring 268 is journaled on the closure tube260 and serves to bias the closure tube 260 in the proximal direction“PD” which can serve to pivot the closure trigger into the unactuatedposition when the shaft assembly is operably coupled to the handleassembly 14.

In at least one form, the interchangeable shaft assembly 200 may furtherinclude an articulation joint 270. Other interchangeable shaftassemblies, however, may not be capable of articulation. As shown inFIG. 7, for example, the articulation joint 270 includes a double pivotclosure sleeve assembly 271. According to various forms, the doublepivot closure sleeve assembly 271 includes an end effector closuresleeve assembly 272 having upper and lower distally projecting tangs273, 274. An end effector closure sleeve assembly 272 includes ahorseshoe aperture 275 and a tab 276 for engaging an opening tab on theanvil 306 in the various manners described in U.S. patent appliationSer. No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541, which has been incorporated byreference herein. As described in further detail therein, the horseshoeaperture 275 and tab 276 engage a tab on the anvil when the anvil 306 isopened. An upper double pivot link 277 includes upwardly projectingdistal and proximal pivot pins that engage respectively an upper distalpin hole in the upper proximally projecting tang 273 and an upperproximal pin hole in an upper distally projecting tang 264 on theclosure tube 260. A lower double pivot link 278 includes upwardlyprojecting distal and proximal pivot pins that engage respectively alower distal pin hole in the lower proximally projecting tang 274 and alower proximal pin hole in the lower distally projecting tang 265. Seealso FIG. 8.

In use, the closure tube 260 is translated distally (direction “DD”) toclose the anvil 306, for example, in response to the actuation of theclosure trigger 32. The anvil 306 is closed by distally translating theclosure tube 260 and thus the shaft closure sleeve assembly 272, causingit to strike a proximal surface on the anvil 360 in the manner describedin the aforementioned reference U.S. patent appliation Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541. Aswas also described in detail in that reference, the anvil 306 is openedby proximally translating the closure tube 260 and the shaft closuresleeve assembly 272, causing tab 276 and the horseshoe aperture 275 tocontact and push against the anvil tab to lift the anvil 306. In theanvil-open position, the shaft closure tube 260 is moved to its proximalposition.

As indicated above, the surgical instrument 10 may further include anarticulation lock 350 of the types and construction described in furtherdetail in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, which can be configured andoperated to selectively lock the end effector 300 in position. Sucharrangement enables the end effector 300 to be rotated, or articulated,relative to the shaft closure tube 260 when the articulation lock 350 isin its unlocked state. In such an unlocked state, the end effector 300can be positioned and pushed against soft tissue and/or bone, forexample, surrounding the surgical site within the patient in order tocause the end effector 300 to articulate relative to the closure tube260. The end effector 300 also may be articulated relative to theclosure tube 260 by an articulation driver 230.

As was also indicated above, the interchangeable shaft assembly 200further includes a firing member 220 that is supported for axial travelwithin the shaft spine 210. The firing member 220 includes anintermediate firing shaft portion 222 that is configured for attachmentto a distal cutting portion or knife bar 280. The firing member 220 alsomay be referred to herein as a “second shaft” and/or a “second shaftassembly”. As shown in FIGS. 8 and 9, the intermediate firing shaftportion 222 may include a longitudinal slot 223 in the distal endthereof which can be configured to receive a tab 284 on the proximal end282 of the distal knife bar 280. The longitudinal slot 223 and theproximal end 282 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint 286. The slip joint 286 canpermit the intermediate firing shaft portion 222 of the firing drive 220to be moved to articulate the end effector 300 without moving, or atleast substantially moving, the knife bar 280. Once the end effector 300has been suitably oriented, the intermediate firing shaft portion 222can be advanced distally until a proximal sidewall of the longitudinalslot 223 comes into contact with the tab 284 in order to advance theknife bar 280 and fire the staple cartridge positioned within thechannel 302 As can be further seen in FIGS. 8 and 9, the shaft spine 210has an elongate opening or window 213 therein to facilitate assembly andinsertion of the intermediate firing shaft portion 222 into the shaftframe 210. Once the intermediate firing shaft portion 222 has beeninserted therein, a top frame segment 215 may be engaged with the shaftframe 212 to enclose the intermediate firing shaft portion 222 and knifebar 280 therein. Further description of the operation of the firingmember 220 may be found in U.S. patent application Ser. No. 13/803,086,now U.S. Patent Application Publication No. 2014/0263541.

Further to the above, the shaft assembly 200 can include a clutchassembly 400 which can be configured to selectively and releasablycouple the articulation driver 230 to the firing member 220. In oneform, the clutch assembly 400 includes a lock collar, or sleeve 402,positioned around the firing member 220 wherein the lock sleeve 402 canbe rotated between an engaged position in which the lock sleeve 402couples the articulation driver 360 to the firing member 220 and adisengaged position in which the articulation driver 360 is not operablycoupled to the firing member 200. When lock sleeve 402 is in its engagedposition, distal movement of the firing member 220 can move thearticulation driver 360 distally and, correspondingly, proximal movementof the firing member 220 can move the articulation driver 230proximally. When lock sleeve 402 is in its disengaged position, movementof the firing member 220 is not transmitted to the articulation driver230 and, as a result, the firing member 220 can move independently ofthe articulation driver 230. In various circumstances, the articulationdriver 230 can be held in position by the articulation lock 350 when thearticulation driver 230 is not being moved in the proximal or distaldirections by the firing member 220.

Referring primarily to FIG. 9, the lock sleeve 402 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 403 defined therein configured to receive thefiring member 220. The lock sleeve 402 can comprisediametrically-opposed, inwardly-facing lock protrusions 404 and anoutwardly-facing lock member 406. The lock protrusions 404 can beconfigured to be selectively engaged with the firing member 220. Moreparticularly, when the lock sleeve 402 is in its engaged position, thelock protrusions 404 are positioned within a drive notch 224 defined inthe firing member 220 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member 220 to the locksleeve 402. When the lock sleeve 402 is in its engaged position, thesecond lock member 406 is received within a drive notch 232 defined inthe articulation driver 230 such that the distal pushing force and/orthe proximal pulling force applied to the lock sleeve 402 can betransmitted to the articulation driver 230. In effect, the firing member220, the lock sleeve 402, and the articulation driver 230 will movetogether when the lock sleeve 402 is in its engaged position. On theother hand, when the lock sleeve 402 is in its disengaged position, thelock protrusions 404 may not be positioned within the drive notch 224 ofthe firing member 220 and, as a result, a distal pushing force and/or aproximal pulling force may not be transmitted from the firing member 220to the lock sleeve 402. Correspondingly, the distal pushing force and/orthe proximal pulling force may not be transmitted to the articulationdriver 230. In such circumstances, the firing member 220 can be slidproximally and/or distally relative to the lock sleeve 402 and theproximal articulation driver 230.

As shown in FIGS. 8-12, the shaft assembly 200 further includes a switchdrum 500 that is rotatably received on the closure tube 260. The switchdrum 500 comprises a hollow shaft segment 502 that has a shaft boss 504formed thereon for receive an outwardly protruding actuation pin 410therein. In various circumstances, the actuation pin 410 extends througha slot 267 into a longitudinal slot 408 provided in the lock sleeve 402to facilitate axial movement of the lock sleeve 402 when it is engagedwith the articulation driver 230. A rotary torsion spring 420 isconfigured to engage the boss 504 on the switch drum 500 and a portionof the nozzle housing 203 as shown in FIG. 10 to apply a biasing forceto the switch drum 500. The switch drum 500 can further comprise atleast partially circumferential openings 506 defined therein which,referring to FIGS. 5 and 6, can be configured to receive circumferentialmounts 204, 205 extending from the nozzle halves 202, 203 and permitrelative rotation, but not translation, between the switch drum 500 andthe proximal nozzle 201. As shown in those Figures, the mounts 204 and205 also extend through openings 266 in the closure tube 260 to beseated in recesses 211 in the shaft spine 210. However, rotation of thenozzle 201 to a point where the mounts 204, 205 reach the end of theirrespective slots 506 in the switch drum 500 will result in rotation ofthe switch drum 500 about the shaft axis SA-SA. Rotation of the switchdrum 500 will ultimately result in the rotation of eth actuation pin 410and the lock sleeve 402 between its engaged and disengaged positions.Thus, in essence, the nozzle 201 may be employed to operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentappliation Ser. No. 13/803,086, now U.S. Patent Application PublicationNo. 2014/0263541.

As also illustrated in FIGS. 8-12, the shaft assembly 200 can comprise aslip ring assembly 600 which can be configured to conduct electricalpower to and/or from the end effector 300 and/or communicate signals toand/or from the end effector 300, for example. The slip ring assembly600 can comprise a proximal connector flange 604 mounted to a chassisflange 242 extending from the chassis 240 and a distal connector flange601 positioned within a slot defined in the shaft housings 202, 203. Theproximal connector flange 604 can comprise a first face and the distalconnector flange 601 can comprise a second face which is positionedadjacent to and movable relative to the first face. The distal connectorflange 601 can rotate relative to the proximal connector flange 604about the shaft axis SA-SA. The proximal connector flange 604 cancomprise a plurality of concentric, or at least substantiallyconcentric, conductors 602 defined in the first face thereof. Aconnector 607 can be mounted on the proximal side of the connectorflange 601 and may have a plurality of contacts (not shown) wherein eachcontact corresponds to and is in electrical contact with one of theconductors 602. Such an arrangement permits relative rotation betweenthe proximal connector flange 604 and the distal connector flange 601while maintaining electrical contact therebetween. The proximalconnector flange 604 can include an electrical connector 606 which canplace the conductors 602 in signal communication with a shaft circuitboard 610 mounted to the shaft chassis 240, for example. In at least oneinstance, a wiring harness comprising a plurality of conductors canextend between the electrical connector 606 and the shaft circuit board610. The electrical connector 606 may extend proximally through aconnector opening 243 defined in the chassis mounting flange 242. SeeFIG. 7. U.S. patent appliation Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, nowU.S. Patent Application Publication No. 2014/0263552, is incorporated byreference in its entirety. U.S. patent appliation Ser. No. 13/800,025,entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar.13, 2013, now U.S. Pat. No. 9,345,481, is incorporated by reference inits entirety. Further details regarding slip ring assembly 600 may befound in U.S. patent appliation Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541.

As discussed above, the shaft assembly 200 can include a proximalportion which is fixably mounted to the handle assembly 14 and a distalportion which is rotatable about a longitudinal axis. The rotatabledistal shaft portion can be rotated relative to the proximal portionabout the slip ring assembly 600, as discussed above. The distalconnector flange 601 of the slip ring assembly 600 can be positionedwithin the rotatable distal shaft portion. Moreover, further to theabove, the switch drum 500 can also be positioned within the rotatabledistal shaft portion. When the rotatable distal shaft portion isrotated, the distal connector flange 601 and the switch drum 500 can berotated synchronously with one another. In addition, the switch drum 500can be rotated between a first position and a second position relativeto the distal connector flange 601. When the switch drum 500 is in itsfirst position, the articulation drive system may be operably disengagedfrom the firing drive system and, thus, the operation of the firingdrive system may not articulate the end effector 300 of the shaftassembly 200. When the switch drum 500 is in its second position, thearticulation drive system may be operably engaged with the firing drivesystem and, thus, the operation of the firing drive system mayarticulate the end effector 300 of the shaft assembly 200. When theswitch drum 500 is moved between its first position and its secondposition, the switch drum 500 is moved relative to distal connectorflange 601. In various instances, the shaft assembly 200 can comprise atleast one sensor configured to detect the position of the switch drum500. Turning now to FIGS. 11 and 12, the distal connector flange 601 cancomprise a magnetic field sensor 605, for example, and the switch drum500 can comprise a magnetic element, such as permanent magnet 505, forexample. The magnetic field sensor 605 can be configured to detect theposition of the permanent magnet 505. When the switch drum 500 isrotated between its first position and its second position, thepermanent magnet 505 can move relative to the magnetic field sensor 605.In various instances, magnetic field sensor 605 can detect changes in amagnetic field created when the permanent magnet 505 is moved. Themagnetic field sensor 605 can be in signal communication with the shaftcircuit board 610 and/or the handle circuit board 100, for example.Based on the signal from the magnetic field sensor 605, amicrocontroller on the shaft circuit board 610 and/or the handle circuitboard 100 can determine whether the articulation drive system is engagedwith or disengaged from the firing drive system.

Referring again to FIGS. 3 and 7, the chassis 240 includes at least one,and preferably two, tapered attachment portions 244 formed thereon thatare adapted to be received within corresponding dovetail slots 702formed within a distal attachment flange portion 700 of the frame 20.Each dovetail slot 702 may be tapered or, stated another way, besomewhat V-shaped to seatingly receive the attachment portions 244therein. As can be further seen in FIGS. 3 and 7, a shaft attachment lug226 is formed on the proximal end of the intermediate firing shaft 222.As will be discussed in further detail below, when the interchangeableshaft assembly 200 is coupled to the handle assembly 14, the shaftattachment lug 226 is received in a firing shaft attachment cradle 126formed in the distal end 125 of the longitudinal drive member 120 asshown in FIGS. 3 and 6, for example.

Various shaft assemblies employ a latch system 710 for removablycoupling the shaft assembly 200 to the housing 12 and more specificallyto the frame 20. As shown in FIG. 7, for example, in at least one form,the latch system 710 includes a lock member or lock yoke 712 that ismovably coupled to the chassis 240. In the illustrated example, forexample, the lock yoke 712 has a U-shape with two spaced downwardlyextending legs 714. The legs 714 each have a pivot lug 716 formedthereon that are adapted to be received in corresponding holes 245formed in the chassis 240. Such arrangement facilitates pivotalattachment of the lock yoke 712 to the chassis 240. The lock yoke 712may include two proximally protruding lock lugs 714 that are configuredfor releasable engagement with corresponding lock detents or grooves 704in the distal attachment flange 700 of the frame 20. See FIG. 3. Invarious forms, the lock yoke 712 is biased in the proximal direction byspring or biasing member (not shown). Actuation of the lock yoke 712 maybe accomplished by a latch button 722 that is slidably mounted on alatch actuator assembly 720 that is mounted to the chassis 240. Thelatch button 722 may be biased in a proximal direction relative to thelock yoke 712. As will be discussed in further detail below, the lockyoke 712 may be moved to an unlocked position by biasing the latchbutton the in distal direction which also causes the lock yoke 712 topivot out of retaining engagement with the distal attachment flange 700of the frame 20. When the lock yoke 712 is in “retaining engagement”with the distal attachment flange 700 of the frame 20, the lock lugs 716are retainingly seated within the corresponding lock detents or grooves704 in the distal attachment flange 700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 32 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 300 in a desiredorientation, the clinician may then fully actuate the closure trigger 32to close the anvil 306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 30 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 200 from the housing 12. One form of the latchsystem 710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 7, the lock yoke 712 includesat least one and preferably two lock hooks 718 that are adapted tocontact corresponding lock lug portions 256 that are formed on theclosure shuttle 250. Referring to FIGS. 13-15, when the closure shuttle250 is in an unactuated position (i.e., the first drive system 30 isunactuated and the anvil 306 is open), the lock yoke 712 may be pivotedin a distal direction to unlock the interchangeable shaft assembly 200from the housing 12. When in that position, the lock hooks 718 do notcontact the lock lug portions 256 on the closure shuttle 250. However,when the closure shuttle 250 is moved to an actuated position (i.e., thefirst drive system 30 is actuated and the anvil 306 is in the closedposition), the lock yoke 712 is prevented from being pivoted to anunlocked position. See FIGS. 16-18. Stated another way, if the clinicianwere to attempt to pivot the lock yoke 712 to an unlocked position or,for example, the lock yoke 712 was in advertently bumped or contacted ina manner that might otherwise cause it to pivot distally, the lock hooks718 on the lock yoke 712 will contact the lock lugs 256 on the closureshuttle 250 and prevent movement of the lock yoke 712 to an unlockedposition.

Attachment of the interchangeable shaft assembly 200 to the handleassembly 14 will now be described with reference to FIG. 3. To commencethe coupling process, the clinician may position the chassis 240 of theinterchangeable shaft assembly 200 above or adjacent to the distalattachment flange 700 of the frame 20 such that the tapered attachmentportions 244 formed on the chassis 240 are aligned with the dovetailslots 702 in the frame 20. The clinician may then move the shaftassembly 200 along an installation axis IA that is perpendicular to theshaft axis SA-SA to seat the attachment portions 244 in “operableengagement” with the corresponding dovetail receiving slots 702. Indoing so, the shaft attachment lug 226 on the intermediate firing shaft222 will also be seated in the cradle 126 in the longitudinally movabledrive member 120 and the portions of pin 37 on the second closure link38 will be seated in the corresponding hooks 252 in the closure yoke250. As used herein, the term “operable engagement” in the context oftwo components means that the two components are sufficiently engagedwith each other so that upon application of an actuation motion thereto,the components may carry out their intended action, function and/orprocedure.

As discussed above, at least five systems of the interchangeable shaftassembly 200 can be operably coupled with at least five correspondingsystems of the handle assembly 14. A first system can comprise a framesystem which couples and/or aligns the frame or spine of the shaftassembly 200 with the frame 20 of the handle assembly 14. Another systemcan comprise a closure drive system 30 which can operably connect theclosure trigger 32 of the handle assembly 14 and the closure tube 260and the anvil 306 of the shaft assembly 200. As outlined above, theclosure tube attachment yoke 250 of the shaft assembly 200 can beengaged with the pin 37 on the second closure link 38. Another systemcan comprise the firing drive system 80 which can operably connect thefiring trigger 130 of the handle assembly 14 with the intermediatefiring shaft 222 of the shaft assembly 200.

As outlined above, the shaft attachment lug 226 can be operablyconnected with the cradle 126 of the longitudinal drive member 120.Another system can comprise an electrical system which can signal to acontroller in the handle assembly 14, such as microcontroller, forexample, that a shaft assembly, such as shaft assembly 200, for example,has been operably engaged with the handle assembly 14 and/or, two,conduct power and/or communication signals between the shaft assembly200 and the handle assembly 14. For instance, the shaft assembly 200 caninclude an electrical connector 1410 that is operably mounted to theshaft circuit board 610. The electrical connector 1410 is configured formating engagement with a corresponding electrical connector 1400 on thehandle control board 100. Further details regaining the circuitry andcontrol systems may be found in U.S. patent appliation Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541,the entire disclosure of which was previously incorporated by referenceherein. The fifth system may consist of the latching system forreleasably locking the shaft assembly 200 to the handle assembly 14.

Referring again to FIGS. 2 and 3, the handle assembly 14 can include anelectrical connector 1400 comprising a plurality of electrical contacts.Turning now to FIG. 19, the electrical connector 1400 can comprise afirst contact 1401 a, a second contact 1401 b, a third contact 1401 c, afourth contact 1401 d, a fifth contact 1401 e, and a sixth contact 1401f, for example. While the illustrated example utilizes six contacts,other examples are envisioned which may utilize more than six contactsor less than six contacts.

As illustrated in FIG. 19, the first contact 1401 a can be in electricalcommunication with a transistor 1408, contacts 1401 b-1401 e can be inelectrical communication with a microcontroller 1500, and the sixthcontact 1401 f can be in electrical communication with a ground. Incertain circumstances, one or more of the electrical contacts 1401b-1401 e may be in electrical communication with one or more outputchannels of the microcontroller 1500 and can be energized, or have avoltage potential applied thereto, when the handle 1042 is in a poweredstate. In some circumstances, one or more of the electrical contacts1401 b-1401 e may be in electrical communication with one or more inputchannels of the microcontroller 1500 and, when the handle assembly 14 isin a powered state, the microcontroller 1500 can be configured to detectwhen a voltage potential is applied to such electrical contacts. When ashaft assembly, such as shaft assembly 200, for example, is assembled tothe handle assembly 14, the electrical contacts 1401 a-1401 f may notcommunicate with each other. When a shaft assembly is not assembled tothe handle assembly 14, however, the electrical contacts 1401 a-1401 fof the electrical connector 1400 may be exposed and, in somecircumstances, one or more of the contacts 1401 a-1401 f may beaccidentally placed in electrical communication with each other. Suchcircumstances can arise when one or more of the contacts 1401 a-1401 fcome into contact with an electrically conductive material, for example.When this occurs, the microcontroller 1500 can receive an erroneousinput and/or the shaft assembly 200 can receive an erroneous output, forexample. To address this issue, in various circumstances, the handleassembly 14 may be unpowered when a shaft assembly, such as shaftassembly 200, for example, is not attached to the handle assembly 14.

In other circumstances, the handle 1042 can be powered when a shaftassembly, such as shaft assembly 200, for example, is not attachedthereto. In such circumstances, the microcontroller 1500 can beconfigured to ignore inputs, or voltage potentials, applied to thecontacts in electrical communication with the microcontroller 1500,i.e., contacts 1401 b-1401 e, for example, until a shaft assembly isattached to the handle assembly 14. Even though the microcontroller 1500may be supplied with power to operate other functionalities of thehandle assembly 14 in such circumstances, the handle assembly 14 may bein a powered-down state. In a way, the electrical connector 1400 may bein a powered-down state as voltage potentials applied to the electricalcontacts 1401 b-1401 e may not affect the operation of the handleassembly 14. The reader will appreciate that, even though contacts 1401b-1401 e may be in a powered-down state, the electrical contacts 1401 aand 1401 f, which are not in electrical communication with themicrocontroller 1500, may or may not be in a powered-down state. Forinstance, sixth contact 1401 f may remain in electrical communicationwith a ground regardless of whether the handle assembly 14 is in apowered-up or a powered-down state.

Furthermore, the transistor 1408, and/or any other suitable arrangementof transistors, such as transistor 1410, for example, and/or switchesmay be configured to control the supply of power from a power source1404, such as a battery 90 within the handle assembly 14, for example,to the first electrical contact 1401 a regardless of whether the handleassembly 14 is in a powered-up or a powered-down state. In variouscircumstances, the shaft assembly 200, for example, can be configured tochange the state of the transistor 1408 when the shaft assembly 200 isengaged with the handle assembly 14. In certain circumstances, furtherto the below, a magnetic field sensor 1402 can be configured to switchthe state of transistor 1410 which, as a result, can switch the state oftransistor 1408 and ultimately supply power from power source 1404 tofirst contact 1401 a. In this way, both the power circuits and thesignal circuits to the connector 1400 can be powered down when a shaftassembly is not installed to the handle assembly 14 and powered up whena shaft assembly is installed to the handle assembly 14.

In various circumstances, referring again to FIG. 19, the handleassembly 14 can include the magnetic field sensor 1402, for example,which can be configured to detect a detectable element, such as amagnetic element 1407 (FIG. 3), for example, on a shaft assembly, suchas shaft assembly 200, for example, when the shaft assembly is coupledto the handle assembly 14. The magnetic field sensor 1402 can be poweredby a power source 1406, such as a battery, for example, which can, ineffect, amplify the detection signal of the magnetic field sensor 1402and communicate with an input channel of the microcontroller 1500 viathe circuit illustrated in FIG. 19. Once the microcontroller 1500 has areceived an input indicating that a shaft assembly has been at leastpartially coupled to the handle assembly 14, and that, as a result, theelectrical contacts 1401 a-1401 f are no longer exposed, themicrocontroller 1500 can enter into its normal, or powered-up, operatingstate. In such an operating state, the microcontroller 1500 willevaluate the signals transmitted to one or more of the contacts 1401b-1401 e from the shaft assembly and/or transmit signals to the shaftassembly through one or more of the contacts 1401 b-1401 e in normal usethereof. In various circumstances, the shaft assembly 200 may have to befully seated before the magnetic field sensor 1402 can detect themagnetic element 1407. While a magnetic field sensor 1402 can beutilized to detect the presence of the shaft assembly 200, any suitablesystem of sensors and/or switches can be utilized to detect whether ashaft assembly has been assembled to the handle assembly 14, forexample. In this way, further to the above, both the power circuits andthe signal circuits to the connector 1400 can be powered down when ashaft assembly is not installed to the handle assembly 14 and powered upwhen a shaft assembly is installed to the handle assembly 14.

In various examples, as may be used throughout the present disclosure,any suitable magnetic field sensor may be employed to detect whether ashaft assembly has been assembled to the handle assembly 14, forexample. For example, the technologies used for magnetic field sensinginclude Hall effect sensor, search coil, fluxgate, optically pumped,nuclear precession, SQUID, Hall-effect, anisotropic magnetoresistance,giant magnetoresistance, magnetic tunnel junctions, giantmagnetoimpedance, magnetostrictive/piezoelectric composites,magnetodiode, magnetotransistor, fiber optic, magnetooptic, andmicroelectromechanical systems-based magnetic sensors, among others.

Referring to FIG. 19, the microcontroller 1500 may generally comprise amicroprocessor (“processor”) and one or more memory units operationallycoupled to the processor. By executing instruction code stored in thememory, the processor may control various components of the surgicalinstrument, such as the motor, various drive systems, and/or a userdisplay, for example. The microcontroller 1500 may be implemented usingintegrated and/or discrete hardware elements, software elements, and/ora combination of both. Examples of integrated hardware elements mayinclude processors, microprocessors, microcontrollers, integratedcircuits, application specific integrated circuits (ASIC), programmablelogic devices (PLD), digital signal processors (DSP), field programmablegate arrays (FPGA), logic gates, registers, semiconductor devices,chips, microchips, chip sets, microcontrollers, system-on-chip (SoC),and/or system-in-package (SIP). Examples of discrete hardware elementsmay include circuits and/or circuit elements such as logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, and/or relays. In certain instances, the microcontroller 1500may include a hybrid circuit comprising discrete and integrated circuitelements or components on one or more substrates, for example.

Referring to FIG. 19, the microcontroller 1500 may be an LM 4F230H5QR,available from Texas Instruments, for example. In certain instances, theTexas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available. Other microcontrollersmay be readily substituted for use with the present disclosure.Accordingly, the present disclosure should not be limited in thiscontext.

As discussed above, the handle assembly 14 and/or the shaft assembly 200can include systems and configurations configured to prevent, or atleast reduce the possibility of, the contacts of the handle electricalconnector 1400 and/or the contacts of the shaft electrical connector1410 from becoming shorted out when the shaft assembly 200 is notassembled, or completely assembled, to the handle assembly 14. Referringto FIG. 3, the handle electrical connector 1400 can be at leastpartially recessed within a cavity 1409 defined in the handle frame 20.The six contacts 1401 a-1401 f of the electrical connector 1400 can becompletely recessed within the cavity 1409. Such arrangements can reducethe possibility of an object accidentally contacting one or more of thecontacts 1401 a-1401 f. Similarly, the shaft electrical connector 1410can be positioned within a recess defined in the shaft chassis 240 whichcan reduce the possibility of an object accidentally contacting one ormore of the contacts 1411 a-1411 f of the shaft electrical connector1410. With regard to the particular example depicted in FIG. 3, theshaft contacts 1411 a-1411 f can comprise male contacts. In at least oneexample, each shaft contact 1411 a-1411 f can comprise a flexibleprojection extending therefrom which can be configured to engage acorresponding handle contact 1401 a-1401 f, for example. The handlecontacts 1401 a-1401 f can comprise female contacts. In at least oneexample, each handle contact 1401 a-1401 f can comprise a flat surface,for example, against which the male shaft contacts 1401 a-1401 f canwipe, or slide, against and maintain an electrically conductiveinterface therebetween. In various instances, the direction in which theshaft assembly 200 is assembled to the handle assembly 14 can beparallel to, or at least substantially parallel to, the handle contacts1401 a-1401 f such that the shaft contacts 1411 a-1411 f slide againstthe handle contacts 1401 a-1401 f when the shaft assembly 200 isassembled to the handle assembly 14. In various alternative examples,the handle contacts 1401 a-1401 f can comprise male contacts and theshaft contacts 1411 a-1411 f can comprise female contacts. In certainalternative examples, the handle contacts 1401 a-1401 f and the shaftcontacts 1411 a-1411 f can comprise any suitable arrangement ofcontacts.

In various instances, the handle assembly 14 can comprise a connectorguard configured to at least partially cover the handle electricalconnector 1400 and/or a connector guard configured to at least partiallycover the shaft electrical connector 1410. A connector guard canprevent, or at least reduce the possibility of, an object accidentallytouching the contacts of an electrical connector when the shaft assemblyis not assembled to, or only partially assembled to, the handle. Aconnector guard can be movable. For instance, the connector guard can bemoved between a guarded position in which it at least partially guards aconnector and an unguarded position in which it does not guard, or atleast guards less of, the connector. In at least one example, aconnector guard can be displaced as the shaft assembly is beingassembled to the handle. For instance, if the handle comprises a handleconnector guard, the shaft assembly can contact and displace the handleconnector guard as the shaft assembly is being assembled to the handle.Similarly, if the shaft assembly comprises a shaft connector guard, thehandle can contact and displace the shaft connector guard as the shaftassembly is being assembled to the handle. In various instances, aconnector guard can comprise a door, for example. In at least oneinstance, the door can comprise a beveled surface which, when contactedby the handle or shaft, can facilitate the displacement of the door in acertain direction. In various instances, the connector guard can betranslated and/or rotated, for example. In certain instances, aconnector guard can comprise at least one film which covers the contactsof an electrical connector. When the shaft assembly is assembled to thehandle, the film can become ruptured. In at least one instance, the malecontacts of a connector can penetrate the film before engaging thecorresponding contacts positioned underneath the film.

As described above, the surgical instrument can include a system whichcan selectively power-up, or activate, the contacts of an electricalconnector, such as the electrical connector 1400, for example. Invarious instances, the contacts can be transitioned between anunactivated condition and an activated condition. In certain instances,the contacts can be transitioned between a monitored condition, adeactivated condition, and an activated condition. For instance, themicrocontroller 1500, for example, can monitor the contacts 1401 a-1401f when a shaft assembly has not been assembled to the handle assembly 14to determine whether one or more of the contacts 1401 a-1401 f may havebeen shorted. The microcontroller 1500 can be configured to apply a lowvoltage potential to each of the contacts 1401 a-1401 f and assesswhether only a minimal resistance is present at each of the contacts.Such an operating state can comprise the monitored condition. In theevent that the resistance detected at a contact is high, or above athreshold resistance, the microcontroller 1500 can deactivate thatcontact, more than one contact, or, alternatively, all of the contacts.Such an operating state can comprise the deactivated condition. If ashaft assembly is assembled to the handle assembly 14 and it is detectedby the microcontroller 1500, as discussed above, the microcontroller1500 can increase the voltage potential to the contacts 1401 a-1401 fSuch an operating state can comprise the activated condition.

The various shaft assemblies disclosed herein may employ sensors andvarious other components that require electrical communication with thecontroller in the housing. These shaft assemblies generally areconfigured to be able to rotate relative to the housing necessitating aconnection that facilitates such electrical communication between two ormore components that may rotate relative to each other. When employingend effectors of the types disclosed herein, the connector arrangementsmust be relatively robust in nature while also being somewhat compact tofit into the shaft assembly connector portion.

Referring to FIG. 20, a non-limiting form of the end effector 300 isillustrated. As described above, the end effector 300 may include theanvil 306 and the staple cartridge 304. In this non-limiting example,the anvil 306 is coupled to an elongate channel 198. For example,apertures 199 can be defined in the elongate channel 198 which canreceive pins 152 extending from the anvil 306 and allow the anvil 306 topivot from an open position to a closed position relative to theelongate channel 198 and staple cartridge 304. In addition, FIG. 20shows a firing bar 172, configured to longitudinally translate into theend effector 300. The firing bar 172 may be constructed from one solidsection, or in various examples, may include a laminate materialcomprising, for example, a stack of steel plates. A distally projectingend of the firing bar 172 can be attached to an E-beam 178 that can,among other things, assist in spacing the anvil 306 from a staplecartridge 304 positioned in the elongate channel 198 when the anvil 306is in a closed position. The E-beam 178 can also include a sharpenedcutting edge 182 which can be used to sever tissue as the E-beam 178 isadvanced distally by the firing bar 172. In operation, the E-beam 178can also actuate, or fire, the staple cartridge 304. The staplecartridge 304 can include a molded cartridge body 194 that holds aplurality of staples 191 resting upon staple drivers 192 withinrespective upwardly open staple cavities 195. A wedge sled 190 is drivendistally by the E-beam 178, sliding upon a cartridge tray 196 that holdstogether the various components of the replaceable staple cartridge 304.The wedge sled 190 upwardly cams the staple drivers 192 to force out thestaples 191 into deforming contact with the anvil 306 while a cuttingsurface 182 of the E-beam 178 severs clamped tissue.

Further to the above, the E-beam 178 can include upper pins 180 whichengage the anvil 306 during firing. The E-beam 178 can further includemiddle pins 184 and a bottom foot 186 which can engage various portionsof the cartridge body 194, cartridge tray 196 and elongate channel 198.When a staple cartridge 304 is positioned within the elongate channel198, a slot 193 defined in the cartridge body 194 can be aligned with aslot 197 defined in the cartridge tray 196 and a slot 189 defined in theelongate channel 198. In use, the E-beam 178 can slide through thealigned slots 193, 197, and 189 wherein, as indicated in FIG. 20, thebottom foot 186 of the E-beam 178 can engage a groove running along thebottom surface of channel 198 along the length of slot 189, the middlepins 184 can engage the top surfaces of cartridge tray 196 along thelength of longitudinal slot 197, and the upper pins 180 can engage theanvil 306. In such circumstances, the E-beam 178 can space, or limit therelative movement between, the anvil 306 and the staple cartridge 304 asthe firing bar 172 is moved distally to fire the staples from the staplecartridge 304 and/or incise the tissue captured between the anvil 306and the staple cartridge 304. Thereafter, the firing bar 172 and theE-beam 178 can be retracted proximally allowing the anvil 306 to beopened to release the two stapled and severed tissue portions (notshown).

Having described a surgical instrument 10 (FIGS. 1-4) in general terms,the description now turns to a detailed description of variouselectrical/electronic components of the surgical instrument 10. Turningnow to FIGS. 21A-21B, where one example of a segmented circuit 2000comprising a plurality of circuit segments 2002 a-2002 g is illustrated.The segmented circuit 2000 comprising the plurality of circuit segments2002 a-2002 g is configured to control a powered surgical instrument,such as, for example, the surgical instrument 10 illustrated in FIGS.1-18A, without limitation. The plurality of circuit segments 2002 a-2002g is configured to control one or more operations of the poweredsurgical instrument 10. A safety processor segment 2002 a (Segment 1)comprises a safety processor 2004. A primary processor segment 2002 b(Segment 2) comprises a primary processor 2006. The safety processor2004 and/or the primary processor 2006 are configured to interact withone or more additional circuit segments 2002 c-2002 g to controloperation of the powered surgical instrument 10. The primary processor2006 comprises a plurality of inputs coupled to, for example, one ormore circuit segments 2002 c-2002 g, a battery 2008, and/or a pluralityof switches 2058 a-2070. The segmented circuit 2000 may be implementedby any suitable circuit, such as, for example, a printed circuit boardassembly (PCBA) within the powered surgical instrument 10. It should beunderstood that the term processor as used herein includes anymicroprocessor, microcontroller, or other basic computing device thatincorporates the functions of a computer's central processing unit (CPU)on an integrated circuit or at most a few integrated circuits. Theprocessor is a multipurpose, programmable device that accepts digitaldata as input, processes it according to instructions stored in itsmemory, and provides results as output. It is an example of sequentialdigital logic, as it has internal memory. Processors operate on numbersand symbols represented in the binary numeral system.

In one aspect, the main processor 2006 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one example, the safety processor 2004 may be asafety microcontroller platform comprising two microcontroller-basedfamilies such as TMS570 and RM4x known under the trade name Hercules ARMCortex R4, also by Texas Instruments. Nevertheless, other suitablesubstitutes for microcontrollers and safety processor may be employed,without limitation. In one example, the safety processor 2004 may beconfigured specifically for IEC 61508 and ISO 26262 safety criticalapplications, among others, to provide advanced integrated safetyfeatures while delivering scalable performance, connectivity, and memoryoptions.

In certain instances, the main processor 2006 may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle SRAM, internal ROM loadedwith StellarisWare® software, 2 KB EEPROM, one or more PWM modules, oneor more QEI analog, one or more 12-bit ADC with 12 analog inputchannels, among other features that are readily available for theproduct datasheet. Other processors may be readily substituted and,accordingly, the present disclosure should not be limited in thiscontext.

In one aspect, the segmented circuit 2000 comprises an accelerationsegment 2002 c (Segment 3). The acceleration segment 2002 c comprises anacceleration sensor 2022. The acceleration sensor 2022 may comprise, forexample, an accelerometer. The acceleration sensor 2022 is configured todetect movement or acceleration of the powered surgical instrument 10.In some examples, input from the acceleration sensor 2022 is used, forexample, to transition to and from a sleep mode, identify an orientationof the powered surgical instrument, and/or identify when the surgicalinstrument has been dropped. In some examples, the acceleration segment2002 c is coupled to the safety processor 2004 and/or the primaryprocessor 2006.

In one aspect, the segmented circuit 2000 comprises a display segment2002 d (Segment 4). The display segment 2002 d comprises a displayconnector 2024 coupled to the primary processor 2006. The displayconnector 2024 couples the primary processor 2006 to a display 2028through one or more display driver integrated circuits 2026. The displaydriver integrated circuits 2026 may be integrated with the display 2028and/or may be located separately from the display 2028. The display 2028may comprise any suitable display, such as, for example, an organiclight-emitting diode (OLED) display, a liquid-crystal display (LCD),and/or any other suitable display. In some examples, the display segment2002 d is coupled to the safety processor 2004.

In some aspects, the segmented circuit 2000 comprises a shaft segment2002 e (Segment 5). The shaft segment 2002 e comprises one or morecontrols for a shaft 2004 coupled to the surgical instrument 10 and/orone or more controls for an end effector 2006 coupled to the shaft 2004.The shaft segment 2002 e comprises a shaft connector 2030 configured tocouple the primary processor 2006 to a shaft PCBA 2031. The shaft PCBA2031 comprises a first articulation switch 2036, a second articulationswitch 2032, and a shaft PCBA EEPROM 2034. In some examples, the shaftPCBA EEPROM 2034 comprises one or more parameters, routines, and/orprograms specific to the shaft 2004 and/or the shaft PCBA 2031. Theshaft PCBA 2031 may be coupled to the shaft 2004 and/or integral withthe surgical instrument 10. In some examples, the shaft segment 2002 ecomprises a second shaft EEPROM 2038. The second shaft EEPROM 2038comprises a plurality of algorithms, routines, parameters, and/or otherdata corresponding to one or more shafts 2004 and/or end effectors 2006which may be interfaced with the powered surgical instrument 10.

In some aspects, the segmented circuit 2000 comprises a position encodersegment 2002 f (Segment 6). The position encoder segment 2002 fcomprises one or more magnetic rotary position encoders 2040 a-2040 b.The one or more magnetic rotary position encoders 2040 a-2040 b areconfigured to identify the rotational position of a motor 2048, a shaft2004, and/or an end effector 2006 of the surgical instrument 10. In someexamples, the magnetic rotary position encoders 2040 a-2040 b may becoupled to the safety processor 2004 and/or the primary processor 2006.

In some aspects, the segmented circuit 2000 comprises a motor segment2002 g (Segment 7). The motor segment 2002 g comprises a motor 2048configured to control one or more movements of the powered surgicalinstrument 10. The motor 2048 is coupled to the primary processor 2006by an H-Bridge driver 2042 and one or more H-bridge field-effecttransistors (FETs) 2044. The H-bridge FETs 2044 are coupled to thesafety processor 2004. A motor current sensor 2046 is coupled in serieswith the motor 2048 to measure the current draw of the motor 2048. Themotor current sensor 2046 is in signal communication with the primaryprocessor 2006 and/or the safety processor 2004. In some examples, themotor 2048 is coupled to a motor electromagnetic interference (EMI)filter 2050.

In some aspects, the segmented circuit 2000 comprises a power segment2002 h (Segment 8). A battery 2008 is coupled to the safety processor2004, the primary processor 2006, and one or more of the additionalcircuit segments 2002 c-2002 g. The battery 2008 is coupled to thesegmented circuit 2000 by a battery connector 2010 and a current sensor2012. The current sensor 2012 is configured to measure the total currentdraw of the segmented circuit 2000. In some examples, one or morevoltage converters 2014 a, 2014 b, 2016 are configured to providepredetermined voltage values to one or more circuit segments 2002 a-2002g. For example, in some examples, the segmented circuit 2000 maycomprise 3.3V voltage converters 2014 a-2014 b and/or 5V voltageconverters 2016. A boost converter 2018 is configured to provide a boostvoltage up to a predetermined amount, such as, for example, up to 13V.The boost converter 2018 is configured to provide additional voltageand/or current during power intensive operations and prevent brownout orlow-power conditions.

In some aspects, the safety segment 2002 a comprises a motor powerinterrupt 2020. The motor power interrupt 2020 is coupled between thepower segment 2002 h and the motor segment 2002 g. The safety segment2002 a is configured to interrupt power to the motor segment 2002 g whenan error or fault condition is detected by the safety processor 2004and/or the primary processor 2006 as discussed in more detail herein.Although the circuit segments 2002 a-2002 g are illustrated with allcomponents of the circuit segments 2002 a-2002 h located in physicalproximity, one skilled in the art will recognize that a circuit segment2002 a-2002 h may comprise components physically and/or electricallyseparate from other components of the same circuit segment 2002 a-2002g. In some examples, one or more components may be shared between two ormore circuit segments 2002 a-2002 g.

In some aspects, a plurality of switches 2056-2070 are coupled to thesafety processor 2004 and/or the primary processor 2006. The pluralityof switches 2056-2070 may be configured to control one or moreoperations of the surgical instrument 10, control one or more operationsof the segmented circuit 2000, and/or indicate a status of the surgicalinstrument 10. For example, a bail-out door switch 2056 is configured toindicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch2058 a, a left side articulation right switch 2060 a, a left sidearticulation center switch 2062 a, a right side articulation left switch2058 b, a right side articulation right switch 2060 b, and a right sidearticulation center switch 2062 b are configured to control articulationof a shaft 2004 and/or an end effector 2006. A left side reverse switch2064 a and a right side reverse switch 2064 b are coupled to the primaryprocessor 2006. In some examples, the left side switches comprising theleft side articulation left switch 2058 a, the left side articulationright switch 2060 a, the left side articulation center switch 2062 a,and the left side reverse switch 2064 a are coupled to the primaryprocessor 2006 by a left flex connector 2072 a. The right side switchescomprising the right side articulation left switch 2058 b, the rightside articulation right switch 2060 b, the right side articulationcenter switch 2062 b, and the right side reverse switch 2064 b arecoupled to the primary processor 2006 by a right flex connector 2072 b.In some examples, a firing switch 2066, a clamp release switch 2068, anda shaft engaged switch 2070 are coupled to the primary processor 2006.

In some aspects, the plurality of switches 2056-2070 may comprise, forexample, a plurality of handle controls mounted to a handle of thesurgical instrument 10, a plurality of indicator switches, and/or anycombination thereof. In various examples, the plurality of switches2056-2070 allow a surgeon to manipulate the surgical instrument, providefeedback to the segmented circuit 2000 regarding the position and/oroperation of the surgical instrument, and/or indicate unsafe operationof the surgical instrument 10. In some examples, additional or fewerswitches may be coupled to the segmented circuit 2000, one or more ofthe switches 2056-2070 may be combined into a single switch, and/orexpanded to multiple switches. For example, in one example, one or moreof the left side and/or right side articulation switches 2058 a-2064 bmay be combined into a single multi-position switch.

In one aspect, the safety processor 2004 is configured to implement awatchdog function, among other safety operations. The safety processor2004 and the primary processor 2006 of the segmented circuit 2000 are insignal communication. A microprocessor alive heartbeat signal isprovided at output 2096. The acceleration segment 2002 c comprises anaccelerometer 2022 configured to monitor movement of the surgicalinstrument 10. In various examples, the accelerometer 2022 may be asingle, double, or triple axis accelerometer. The accelerometer 2022 maybe employed to measures proper acceleration that is not necessarily thecoordinate acceleration (rate of change of velocity). Instead, theaccelerometer sees the acceleration associated with the phenomenon ofweight experienced by a test mass at rest in the frame of reference ofthe accelerometer 2022. For example, the accelerometer 2022 at rest onthe surface of the earth will measure an acceleration g=9.8 m/s²(gravity) straight upwards, due to its weight. Another type ofacceleration that accelerometer 2022 can measure is g-forceacceleration. In various other examples, the accelerometer 2022 maycomprise a single, double, or triple axis accelerometer. Further, theacceleration segment 2002 c may comprise one or more inertial sensors todetect and measure acceleration, tilt, shock, vibration, rotation, andmultiple degrees-of-freedom (DoF). A suitable inertial sensor maycomprise an accelerometer (single, double, or triple axis), amagnetometer to measure a magnetic field in space such as the earth'smagnetic field, and/or a gyroscope to measure angular velocity.

In one aspect, the safety processor 2004 is configured to implement awatchdog function with respect to one or more circuit segments 2002c-2002 h, such as, for example, the motor segment 2002 g. In thisregards, the safety processor 2004 employs the watchdog function todetect and recover from malfunctions of the primary processor 2006.During normal operation, the safety processor 2004 monitors for hardwarefaults or program errors of the primary processor 2004 and to initiatecorrective action or actions. The corrective actions may include placingthe primary processor 2006 in a safe state and restoring normal systemoperation. In one example, the safety processor 2004 is coupled to atleast a first sensor. The first sensor measures a first property of thesurgical instrument 10 (FIGS. 1-4). In some examples, the safetyprocessor 2004 is configured to compare the measured property of thesurgical instrument 10 to a predetermined value. For example, in oneexample, a motor sensor 2040 a is coupled to the safety processor 2004.The motor sensor 2040 a provides motor speed and position information tothe safety processor 2004. The safety processor 2004 monitors the motorsensor 2040 a and compares the value to a maximum speed and/or positionvalue and prevents operation of the motor 2048 above the predeterminedvalues. In some examples, the predetermined values are calculated basedon real-time speed and/or position of the motor 2048, calculated fromvalues supplied by a second motor sensor 2040 b in communication withthe primary processor 2006, and/or provided to the safety processor 2004from, for example, a memory module coupled to the safety processor 2004.

In some aspects, a second sensor is coupled to the primary processor2006. The second sensor is configured to measure the first physicalproperty. The safety processor 2004 and the primary processor 2006 areconfigured to provide a signal indicative of the value of the firstsensor and the second sensor respectively. When either the safetyprocessor 2004 or the primary processor 2006 indicates a value outsideof an acceptable range, the segmented circuit 2000 prevents operation ofat least one of the circuit segments 2002 c-2002 h, such as, forexample, the motor segment 2002 g. For example, in the exampleillustrated in FIGS. 21A-21B, the safety processor 2004 is coupled to afirst motor position sensor 2040 a and the primary processor 2006 iscoupled to a second motor position sensor 2040 b. The motor positionsensors 2040 a, 2040 b may comprise any suitable motor position sensor,such as, for example, a magnetic angle rotary input comprising a sineand cosine output. The motor position sensors 2040 a, 2040 b providerespective signals to the safety processor 2004 and the primaryprocessor 2006 indicative of the position of the motor 2048.

The safety processor 2004 and the primary processor 2006 generate anactivation signal when the values of the first motor sensor 2040 a andthe second motor sensor 2040 b are within a predetermined range. Wheneither the primary processor 2006 or the safety processor 2004 to detecta value outside of the predetermined range, the activation signal isterminated and operation of at least one circuit segment 2002 c-2002 h,such as, for example, the motor segment 2002 g, is interrupted and/orprevented. For example, in some examples, the activation signal from theprimary processor 2006 and the activation signal from the safetyprocessor 2004 are coupled to an AND gate. The AND gate is coupled to amotor power switch 2020. The AND gate maintains the motor power switch2020 in a closed, or on, position when the activation signal from boththe safety processor 2004 and the primary processor 2006 are high,indicating a value of the motor sensors 2040 a, 2040 b within thepredetermined range. When either of the motor sensors 2040 a, 2040 bdetect a value outside of the predetermined range, the activation signalfrom that motor sensor 2040 a, 2040 b is set low, and the output of theAND gate is set low, opening the motor power switch 2020. In someexamples, the value of the first sensor 2040 a and the second sensor2040 b is compared, for example, by the safety processor 2004 and/or theprimary processor 2006. When the values of the first sensor and thesecond sensor are different, the safety processor 2004 and/or theprimary processor 2006 may prevent operation of the motor segment 2002g.

In some aspects, the safety processor 2004 receives a signal indicativeof the value of the second sensor 2040 b and compares the second sensorvalue to the first sensor value. For example, in one aspect, the safetyprocessor 2004 is coupled directly to a first motor sensor 2040 a. Asecond motor sensor 2040 b is coupled to a primary processor 2006, whichprovides the second motor sensor 2040 b value to the safety processor2004, and/or coupled directly to the safety processor 2004. The safetyprocessor 2004 compares the value of the first motor sensor 2040 to thevalue of the second motor sensor 2040 b. When the safety processor 2004detects a mismatch between the first motor sensor 2040 a and the secondmotor sensor 2040 b, the safety processor 2004 may interrupt operationof the motor segment 2002 g, for example, by cutting power to the motorsegment 2002 g.

In some aspects, the safety processor 2004 and/or the primary processor2006 is coupled to a first sensor 2040 a configured to measure a firstproperty of a surgical instrument and a second sensor 2040 b configuredto measure a second property of the surgical instrument. The firstproperty and the second property comprise a predetermined relationshipwhen the surgical instrument is operating normally. The safety processor2004 monitors the first property and the second property. When a valueof the first property and/or the second property inconsistent with thepredetermined relationship is detected, a fault occurs. When a faultoccurs, the safety processor 2004 takes at least one action, such as,for example, preventing operation of at least one of the circuitsegments, executing a predetermined operation, and/or resetting theprimary processor 2006. For example, the safety processor 2004 may openthe motor power switch 2020 to cut power to the motor circuit segment2002 g when a fault is detected.

In one aspect, the safety processor 2004 is configured to execute anindependent control algorithm. In operation, the safety processor 2004monitors the segmented circuit 2000 and is configured to control and/oroverride signals from other circuit components, such as, for example,the primary processor 2006, independently. The safety processor 2004 mayexecute a preprogrammed algorithm and/or may be updated or programmed onthe fly during operation based on one or more actions and/or positionsof the surgical instrument 10. For example, in one example, the safetyprocessor 2004 is reprogrammed with new parameters and/or safetyalgorithms each time a new shaft and/or end effector is coupled to thesurgical instrument 10. In some examples, one or more safety valuesstored by the safety processor 2004 are duplicated by the primaryprocessor 2006. Two-way error detection is performed to ensure valuesand/or parameters stored by either of the processors 2004, 2006 arecorrect.

In some aspects, the safety processor 2004 and the primary processor2006 implement a redundant safety check. The safety processor 2004 andthe primary processor 2006 provide periodic signals indicating normaloperation. For example, during operation, the safety processor 2004 mayindicate to the primary processor 2006 that the safety processor 2004 isexecuting code and operating normally. The primary processor 2006 may,likewise, indicate to the safety processor 2004 that the primaryprocessor 2006 is executing code and operating normally. In someexamples, communication between the safety processor 2004 and theprimary processor 2006 occurs at a predetermined interval. Thepredetermined interval may be constant or may be variable based on thecircuit state and/or operation of the surgical instrument 10.

FIG. 22 illustrates one example of a power assembly 2100 comprising ausage cycle circuit 2102 configured to monitor a usage cycle count ofthe power assembly 2100. The power assembly 2100 may be coupled to asurgical instrument 2110. The usage cycle circuit 2102 comprises aprocessor 2104 and a use indicator 2106. The use indicator 2106 isconfigured to provide a signal to the processor 2104 to indicate a useof the battery back 2100 and/or a surgical instrument 2110 coupled tothe power assembly 2100. A “use” may comprise any suitable action,condition, and/or parameter such as, for example, changing a modularcomponent of a surgical instrument 2110, deploying or firing adisposable component coupled to the surgical instrument 2110, deliveringelectrosurgical energy from the surgical instrument 2110, reconditioningthe surgical instrument 2110 and/or the power assembly 2100, exchangingthe power assembly 2100, recharging the power assembly 2100, and/orexceeding a safety limitation of the surgical instrument 2110 and/or thebattery back 2100.

In some instances, a usage cycle, or use, is defined by one or morepower assembly 2100 parameters. For example, in one instance, a usagecycle comprises using more than 5% of the total energy available fromthe power assembly 2100 when the power assembly 2100 is at a full chargelevel. In another instance, a usage cycle comprises a continuous energydrain from the power assembly 2100 exceeding a predetermined time limit.For example, a usage cycle may correspond to five minutes of continuousand/or total energy draw from the power assembly 2100. In someinstances, the power assembly 2100 comprises a usage cycle circuit 2102having a continuous power draw to maintain one or more components of theusage cycle circuit 2102, such as, for example, the use indicator 2106and/or a counter 2108, in an active state.

The processor 2104 maintains a usage cycle count. The usage cycle countindicates the number of uses detected by the use indicator 2106 for thepower assembly 2100 and/or the surgical instrument 2110. The processor2104 may increment and/or decrement the usage cycle count based on inputfrom the use indicator 2106. The usage cycle count is used to controlone or more operations of the power assembly 2100 and/or the surgicalinstrument 2110. For example, in some instances, a power assembly 2100is disabled when the usage cycle count exceeds a predetermined usagelimit. Although the instances discussed herein are discussed withrespect to incrementing the usage cycle count above a predeterminedusage limit, those skilled in the art will recognize that the usagecycle count may start at a predetermined amount and may be decrementedby the processor 2104. In this instance, the processor 2104 initiatesand/or prevents one or more operations of the power assembly 2100 whenthe usage cycle count falls below a predetermined usage limit.

The usage cycle count is maintained by a counter 2108. The counter 2108comprises any suitable circuit, such as, for example, a memory module,an analog counter, and/or any circuit configured to maintain a usagecycle count. In some instances, the counter 2108 is formed integrallywith the processor 2104. In other instances, the counter 2108 comprisesa separate component, such as, for example, a solid state memory module.In some instances, the usage cycle count is provided to a remote system,such as, for example, a central database. The usage cycle count istransmitted by a communications module 2112 to the remote system. Thecommunications module 2112 is configured to use any suitablecommunications medium, such as, for example, wired and/or wirelesscommunication. In some instances, the communications module 2112 isconfigured to receive one or more instructions from the remote system,such as, for example, a control signal when the usage cycle countexceeds the predetermined usage limit.

In some instances, the use indicator 2106 is configured to monitor thenumber of modular components used with a surgical instrument 2110coupled to the power assembly 2100. A modular component may comprise,for example, a modular shaft, a modular end effector, and/or any othermodular component. In some instances, the use indicator 2106 monitorsthe use of one or more disposable components, such as, for example,insertion and/or deployment of a staple cartridge within an end effectorcoupled to the surgical instrument 2110. The use indicator 2106comprises one or more sensors for detecting the exchange of one or moremodular and/or disposable components of the surgical instrument 2110.

In some instances, the use indicator 2106 is configured to monitorsingle patient surgical procedures performed while the power assembly2100 is installed. For example, the use indicator 2106 may be configuredto monitor firings of the surgical instrument 2110 while the powerassembly 2100 is coupled to the surgical instrument 2110. A firing maycorrespond to deployment of a staple cartridge, application ofelectrosurgical energy, and/or any other suitable surgical event. Theuse indicator 2106 may comprise one or more circuits for measuring thenumber of firings while the power assembly 2100 is installed. The useindicator 2106 provides a signal to the processor 2104 when a singlepatient procedure is performed and the processor 2104 increments theusage cycle count.

In some instances, the use indicator 2106 comprises a circuit configuredto monitor one or more parameters of the power source 2114, such as, forexample, a current draw from the power source 2114. The one or moreparameters of the power source 2114 correspond to one or more operationsperformable by the surgical instrument 2110, such as, for example, acutting and sealing operation. The use indicator 2106 provides the oneor more parameters to the processor 2104, which increments the usagecycle count when the one or more parameters indicate that a procedurehas been performed.

In some instances, the use indicator 2106 comprises a timing circuitconfigured to increment a usage cycle count after a predetermined timeperiod. The predetermined time period corresponds to a single patientprocedure time, which is the time required for an operator to perform aprocedure, such as, for example, a cutting and sealing procedure. Whenthe power assembly 2100 is coupled to the surgical instrument 2110, theprocessor 2104 polls the use indicator 2106 to determine when the singlepatient procedure time has expired. When the predetermined time periodhas elapsed, the processor 2104 increments the usage cycle count. Afterincrementing the usage cycle count, the processor 2104 resets the timingcircuit of the use indicator 2106.

In some instances, the use indicator 2106 comprises a time constant thatapproximates the single patient procedure time. In one example, theusage cycle circuit 2102 comprises a resistor-capacitor (RC) timingcircuit 2506. The RC timing circuit comprises a time constant defined bya resistor-capacitor pair. The time constant is defined by the values ofthe resistor and the capacitor. In one example, the usage cycle circuit2552 comprises a rechargeable battery and a clock. When the powerassembly 2100 is installed in a surgical instrument, the rechargeablebattery is charged by the power source. The rechargeable batterycomprises enough power to run the clock for at least the single patientprocedure time. The clock may comprise a real time clock, a processorconfigured to implement a time function, or any other suitable timingcircuit.

Referring still to FIG. 22, in some instances, the use indicator 2106comprises a sensor configured to monitor one or more environmentalconditions experienced by the power assembly 2100. For example, the useindicator 2106 may comprise an accelerometer. The accelerometer isconfigured to monitor acceleration of the power assembly 2100. The powerassembly 2100 comprises a maximum acceleration tolerance. Accelerationabove a predetermined threshold indicates, for example, that the powerassembly 2100 has been dropped. When the use indicator 2106 detectsacceleration above the maximum acceleration tolerance, the processor2104 increments a usage cycle count. In some instances, the useindicator 2106 comprises a moisture sensor. The moisture sensor isconfigured to indicate when the power assembly 2100 has been exposed tomoisture. The moisture sensor may comprise, for example, an immersionsensor configured to indicate when the power assembly 2100 has beenfully immersed in a cleaning fluid, a moisture sensor configured toindicate when moisture is in contact with the power assembly 2100 duringuse, and/or any other suitable moisture sensor.

In some instances, the use indicator 2106 comprises a chemical exposuresensor. The chemical exposure sensor is configured to indicate when thepower assembly 2100 has come into contact with harmful and/or dangerouschemicals. For example, during a sterilization procedure, aninappropriate chemical may be used that leads to degradation of thepower assembly 2100. The processor 2104 increments the usage cycle countwhen the use indicator 2106 detects an inappropriate chemical.

In some instances, the usage cycle circuit 2102 is configured to monitorthe number of reconditioning cycles experienced by the power assembly2100. A reconditioning cycle may comprise, for example, a cleaningcycle, a sterilization cycle, a charging cycle, routine and/orpreventative maintenance, and/or any other suitable reconditioningcycle. The use indicator 2106 is configured to detect a reconditioningcycle. For example, the use indicator 2106 may comprise a moisturesensor to detect a cleaning and/or sterilization cycle. In someinstances, the usage cycle circuit 2102 monitors the number ofreconditioning cycles experienced by the power assembly 2100 anddisables the power assembly 2100 after the number of reconditioningcycles exceeds a predetermined threshold.

The usage cycle circuit 2102 may be configured to monitor the number ofpower assembly 2100 exchanges. The usage cycle circuit 2102 incrementsthe usage cycle count each time the power assembly 2100 is exchanged.When the maximum number of exchanges is exceeded the usage cycle circuit2102 locks out the power assembly 2100 and/or the surgical instrument2110. In some instances, when the power assembly 2100 is coupled thesurgical instrument 2110, the usage cycle circuit 2102 identifies theserial number of the power assembly 2100 and locks the power assembly2100 such that the power assembly 2100 is usable only with the surgicalinstrument 2110. In some instances, the usage cycle circuit 2102increments the usage cycle each time the power assembly 2100 is removedfrom and/or coupled to the surgical instrument 2110.

In some instances, the usage cycle count corresponds to sterilization ofthe power assembly 2100. The use indicator 2106 comprises a sensorconfigured to detect one or more parameters of a sterilization cycle,such as, for example, a temperature parameter, a chemical parameter, amoisture parameter, and/or any other suitable parameter. The processor2104 increments the usage cycle count when a sterilization parameter isdetected. The usage cycle circuit 2102 disables the power assembly 2100after a predetermined number of sterilizations. In some instances, theusage cycle circuit 2102 is reset during a sterilization cycle, avoltage sensor to detect a recharge cycle, and/or any suitable sensor.The processor 2104 increments the usage cycle count when areconditioning cycle is detected. The usage cycle circuit 2102 isdisabled when a sterilization cycle is detected. The usage cycle circuit2102 is reactivated and/or reset when the power assembly 2100 is coupledto the surgical instrument 2110. In some instances, the use indicatorcomprises a zero power indicator. The zero power indicator changes stateduring a sterilization cycle and is checked by the processor 2104 whenthe power assembly 2100 is coupled to a surgical instrument 2110. Whenthe zero power indicator indicates that a sterilization cycle hasoccurred, the processor 2104 increments the usage cycle count.

A counter 2108 maintains the usage cycle count. In some instances, thecounter 2108 comprises a non-volatile memory module. The processor 2104increments the usage cycle count stored in the non-volatile memorymodule each time a usage cycle is detected. The memory module may beaccessed by the processor 2104 and/or a control circuit, such as, forexample, the control circuit 200. When the usage cycle count exceeds apredetermined threshold, the processor 2104 disables the power assembly2100. In some instances, the usage cycle count is maintained by aplurality of circuit components. For example, in one instance, thecounter 2108 comprises a resistor (or fuse) pack. After each use of thepower assembly 2100, a resistor (or fuse) is burned to an open position,changing the resistance of the resistor pack. The power assembly 2100and/or the surgical instrument 2110 reads the remaining resistance. Whenthe last resistor of the resistor pack is burned out, the resistor packhas a predetermined resistance, such as, for example, an infiniteresistance corresponding to an open circuit, which indicates that thepower assembly 2100 has reached its usage limit. In some instances, theresistance of the resistor pack is used to derive the number of usesremaining.

In some instances, the usage cycle circuit 2102 prevents further use ofthe power assembly 2100 and/or the surgical instrument 2110 when theusage cycle count exceeds a predetermined usage limit. In one instance,the usage cycle count associated with the power assembly 2100 isprovided to an operator, for example, utilizing a screen formedintegrally with the surgical instrument 2110. The surgical instrument2110 provides an indication to the operator that the usage cycle counthas exceeded a predetermined limit for the power assembly 2100, andprevents further operation of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured tophysically prevent operation when the predetermined usage limit isreached. For example, the power assembly 2100 may comprise a shieldconfigured to deploy over contacts of the power assembly 2100 when theusage cycle count exceeds the predetermined usage limit. The shieldprevents recharge and use of the power assembly 2100 by covering theelectrical connections of the power assembly 2100.

In some instances, the usage cycle circuit 2102 is located at leastpartially within the surgical instrument 2110 and is configured tomaintain a usage cycle count for the surgical instrument 2110. FIG. 22illustrates one or more components of the usage cycle circuit 2102within the surgical instrument 2110 in phantom, illustrating thealternative positioning of the usage cycle circuit 2102. When apredetermined usage limit of the surgical instrument 2110 is exceeded,the usage cycle circuit 2102 disables and/or prevents operation of thesurgical instrument 2110. The usage cycle count is incremented by theusage cycle circuit 2102 when the use indicator 2106 detects a specificevent and/or requirement, such as, for example, firing of the surgicalinstrument 2110, a predetermined time period corresponding to a singlepatient procedure time, based on one or more motor parameters of thesurgical instrument 2110, in response to a system diagnostic indicatingthat one or more predetermined thresholds are met, and/or any othersuitable requirement. As discussed above, in some instances, the useindicator 2106 comprises a timing circuit corresponding to a singlepatient procedure time. In other instances, the use indicator 2106comprises one or more sensors configured to detect a specific eventand/or condition of the surgical instrument 2110.

In some instances, the usage cycle circuit 2102 is configured to preventoperation of the surgical instrument 2110 after the predetermined usagelimit is reached. In some instances, the surgical instrument 2110comprises a visible indicator to indicate when the predetermined usagelimit has been reached and/or exceeded. For example, a flag, such as ared flag, may pop-up from the surgical instrument 2110, such as from thehandle, to provide a visual indication to the operator that the surgicalinstrument 2110 has exceeded the predetermined usage limit. As anotherexample, the usage cycle circuit 2102 may be coupled to a display formedintegrally with the surgical instrument 2110. The usage cycle circuit2102 displays a message indicating that the predetermined usage limithas been exceeded. The surgical instrument 2110 may provide an audibleindication to the operator that the predetermined usage limit has beenexceeded. For example, in one instance, the surgical instrument 2110emits an audible tone when the predetermined usage limit is exceeded andthe power assembly 2100 is removed from the surgical instrument 2110.The audible tone indicates the last use of the surgical instrument 2110and indicates that the surgical instrument 2110 should be disposed orreconditioned.

In some instances, the usage cycle circuit 2102 is configured totransmit the usage cycle count of the surgical instrument 2110 to aremote location, such as, for example, a central database. The usagecycle circuit 2102 comprises a communications module 2112 configured totransmit the usage cycle count to the remote location. Thecommunications module 2112 may utilize any suitable communicationssystem, such as, for example, wired or wireless communications system.The remote location may comprise a central database configured tomaintain usage information. In some instances, when the power assembly2100 is coupled to the surgical instrument 2110, the power assembly 2100records a serial number of the surgical instrument 2110. The serialnumber is transmitted to the central database, for example, when thepower assembly 2100 is coupled to a charger. In some instances, thecentral database maintains a count corresponding to each use of thesurgical instrument 2110. For example, a bar code associated with thesurgical instrument 2110 may be scanned each time the surgicalinstrument 2110 is used. When the use count exceeds a predeterminedusage limit, the central database provides a signal to the surgicalinstrument 2110 indicating that the surgical instrument 2110 should bediscarded.

The surgical instrument 2110 may be configured to lock and/or preventoperation of the surgical instrument 2110 when the usage cycle countexceeds a predetermined usage limit. In some instances, the surgicalinstrument 2110 comprises a disposable instrument and is discarded afterthe usage cycle count exceeds the predetermined usage limit. In otherinstances, the surgical instrument 2110 comprises a reusable surgicalinstrument which may be reconditioned after the usage cycle countexceeds the predetermined usage limit. The surgical instrument 2110initiates a reversible lockout after the predetermined usage limit ismet. A technician reconditions the surgical instrument 2110 and releasesthe lockout, for example, utilizing a specialized technician keyconfigured to reset the usage cycle circuit 2102.

In some aspects, the segmented circuit 2000 is configured for sequentialstart-up. An error check is performed by each circuit segment 2002a-2002 g prior to energizing the next sequential circuit segment 2002a-2002 g. FIG. 23 illustrates one example of a process for sequentiallyenergizing a segmented circuit 2270, such as, for example, the segmentedcircuit 2000. When a battery 2008 is coupled to the segmented circuit2000, the safety processor 2004 is energized 2272. The safety processor2004 performs a self-error check 2274. When an error is detected 2276 a,the safety processor stops energizing the segmented circuit 2000 andgenerates an error code 2278 a. When no errors are detected 2276 b, thesafety processor 2004 initiates 2278 b power-up of the primary processor2006. The primary processor 2006 performs a self-error check. When noerrors are detected, the primary processor 2006 begins sequentialpower-up of each of the remaining circuit segments 2278 b. Each circuitsegment is energized and error checked by the primary processor 2006.When no errors are detected, the next circuit segment is energized 2278b. When an error is detected, the safety processor 2004 and/or theprimary process stops energizing the current segment and generates anerror 2278 a. The sequential start-up continues until all of the circuitsegments 2002 a-2002 g have been energized. In some examples, thesegmented circuit 2000 transitions from sleep mode following a similarsequential power-up process 11250.

FIG. 24 illustrates one aspect of a power segment 2302 comprising aplurality of daisy chained power converters 2314, 2316, 2318. The powersegment 2302 comprises a battery 2308. The battery 2308 is configured toprovide a source voltage, such as, for example, 12V. A current sensor2312 is coupled to the battery 2308 to monitor the current draw of asegmented circuit and/or one or more circuit segments. The currentsensor 2312 is coupled to an FET switch 2313. The battery 2308 iscoupled to one or more voltage converters 2309, 2314, 2316. An always onconverter 2309 provides a constant voltage to one or more circuitcomponents, such as, for example, a motion sensor 2322. The always onconverter 2309 comprises, for example, a 3.3V converter. The always onconverter 2309 may provide a constant voltage to additional circuitcomponents, such as, for example, a safety processor (not shown). Thebattery 2308 is coupled to a boost converter 2318. The boost converter2318 is configured to provide a boosted voltage above the voltageprovided by the battery 2308. For example, in the illustrated example,the battery 2308 provides a voltage of 12V. The boost converter 2318 isconfigured to boost the voltage to 13V. The boost converter 2318 isconfigured to maintain a minimum voltage during operation of a surgicalinstrument, for example, the surgical instrument 10 (FIGS. 1-4).Operation of a motor can result in the power provided to the primaryprocessor 2306 dropping below a minimum threshold and creating abrownout or reset condition in the primary processor 2306. The boostconverter 2318 ensures that sufficient power is available to the primaryprocessor 2306 and/or other circuit components, such as the motorcontroller 2343, during operation of the surgical instrument 10. In someexamples, the boost converter 2318 is coupled directly one or morecircuit components, such as, for example, an OLED display 2388.

The boost converter 2318 is coupled to one or more step-down convertersto provide voltages below the boosted voltage level. A first voltageconverter 2316 is coupled to the boost converter 2318 and provides afirst stepped-down voltage to one or more circuit components. In theillustrated example, the first voltage converter 2316 provides a voltageof 5V. The first voltage converter 2316 is coupled to a rotary positionencoder 2340. A FET switch 2317 is coupled between the first voltageconverter 2316 and the rotary position encoder 2340. The FET switch 2317is controlled by the processor 2306. The processor 2306 opens the FETswitch 2317 to deactivate the position encoder 2340, for example, duringpower intensive operations. The first voltage converter 2316 is coupledto a second voltage converter 2314 configured to provide a secondstepped-down voltage. The second stepped-down voltage comprises, forexample, 3.3V. The second voltage converter 2314 is coupled to aprocessor 2306. In some examples, the boost converter 2318, the firstvoltage converter 2316, and the second voltage converter 2314 arecoupled in a daisy chain configuration. The daisy chain configurationallows the use of smaller, more efficient converters for generatingvoltage levels below the boosted voltage level. The examples, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

FIG. 25 illustrates one aspect of a segmented circuit 2400 configured tomaximize power available for critical and/or power intense functions.The segmented circuit 2400 comprises a battery 2408. The battery 2408 isconfigured to provide a source voltage such as, for example, 12V. Thesource voltage is provided to a plurality of voltage converters 2409,2418. An always-on voltage converter 2409 provides a constant voltage toone or more circuit components, for example, a motion sensor 2422 and asafety processor 2404. The always-on voltage converter 2409 is directlycoupled to the battery 2408. The always-on converter 2409 provides avoltage of 3.3V, for example. The examples, however, are not limited tothe particular voltage range(s) described in the context of thisspecification.

The segmented circuit 2400 comprises a boost converter 2418. The boostconverter 2418 provides a boosted voltage above the source voltageprovided by the battery 2408, such as, for example, 13V. The boostconverter 2418 provides a boosted voltage directly to one or morecircuit components, such as, for example, an OLED display 2488 and amotor controller 2443. By coupling the OLED display 2488 directly to theboost converter 2418, the segmented circuit 2400 eliminates the need fora power converter dedicated to the OLED display 2488. The boostconverter 2418 provides a boosted voltage to the motor controller 2443and the motor 2448 during one or more power intensive operations of themotor 2448, such as, for example, a cutting operation. The boostconverter 2418 is coupled to a step-down converter 2416. The step-downconverter 2416 is configured to provide a voltage below the boostedvoltage to one or more circuit components, such as, for example, 5V. Thestep-down converter 2416 is coupled to, for example, a FET switch 2451and a position encoder 2440. The FET switch 2451 is coupled to theprimary processor 2406. The primary processor 2406 opens the FET switch2451 when transitioning the segmented circuit 2400 to sleep mode and/orduring power intensive functions requiring additional voltage deliveredto the motor 2448. Opening the FET switch 2451 deactivates the positionencoder 2440 and eliminates the power draw of the position encoder 2440.The examples, however, are not limited to the particular voltagerange(s) described in the context of this specification.

The step-down converter 2416 is coupled to a linear converter 2414. Thelinear converter 2414 is configured to provide a voltage of, forexample, 3.3V. The linear converter 2414 is coupled to the primaryprocessor 2406. The linear converter 2414 provides an operating voltageto the primary processor 2406. The linear converter 2414 may be coupledto one or more additional circuit components. The examples, however, arenot limited to the particular voltage range(s) described in the contextof this specification.

The segmented circuit 2400 comprises a bailout switch 2456. The bailoutswitch 2456 is coupled to a bailout door on the surgical instrument 10.The bailout switch 2456 and the safety processor 2404 are coupled to anAND gate 2419. The AND gate 2419 provides an input to a FET switch 2413.When the bailout switch 2456 detects a bailout condition, the bailoutswitch 2456 provides a bailout shutdown signal to the AND gate 2419.When the safety processor 2404 detects an unsafe condition, such as, forexample, due to a sensor mismatch, the safety processor 2404 provides ashutdown signal to the AND gate 2419. In some examples, both the bailoutshutdown signal and the shutdown signal are high during normal operationand are low when a bailout condition or an unsafe condition is detected.When the output of the AND gate 2419 is low, the FET switch 2413 isopened and operation of the motor 2448 is prevented. In some examples,the safety processor 2404 utilizes the shutdown signal to transition themotor 2448 to an off state in sleep mode. A third input to the FETswitch 2413 is provided by a current sensor 2412 coupled to the battery2408. The current sensor 2412 monitors the current drawn by the circuit2400 and opens the FET switch 2413 to shut-off power to the motor 2448when an electrical current above a predetermined threshold is detected.The FET switch 2413 and the motor controller 2443 are coupled to a bankof FET switches 2445 configured to control operation of the motor 2448.

A motor current sensor 2446 is coupled in series with the motor 2448 toprovide a motor current sensor reading to a current monitor 2447. Thecurrent monitor 2447 is coupled to the primary processor 2406. Thecurrent monitor 2447 provides a signal indicative of the current draw ofthe motor 2448. The primary processor 2406 may utilize the signal fromthe motor current 2447 to control operation of the motor, for example,to ensure the current draw of the motor 2448 is within an acceptablerange, to compare the current draw of the motor 2448 to one or moreother parameters of the circuit 2400 such as, for example, the positionencoder 2440, and/or to determine one or more parameters of a treatmentsite. In some examples, the current monitor 2447 may be coupled to thesafety processor 2404.

In some aspects, actuation of one or more handle controls, such as, forexample, a firing trigger, causes the primary processor 2406 to decreasepower to one or more components while the handle control is actuated.For example, in one example, a firing trigger controls a firing strokeof a cutting member. The cutting member is driven by the motor 2448.Actuation of the firing trigger results in forward operation of themotor 2448 and advancement of the cutting member. During firing, theprimary processor 2406 closes the FET switch 2451 to remove power fromthe position encoder 2440. The deactivation of one or more circuitcomponents allows higher power to be delivered to the motor 2448. Whenthe firing trigger is released, full power is restored to thedeactivated components, for example, by closing the FET switch 2451 andreactivating the position encoder 2440.

In some aspects, the safety processor 2404 controls operation of thesegmented circuit 2400. For example, the safety processor 2404 mayinitiate a sequential power-up of the segmented circuit 2400, transitionof the segmented circuit 2400 to and from sleep mode, and/or mayoverride one or more control signals from the primary processor 2406.For example, in the illustrated example, the safety processor 2404 iscoupled to the step-down converter 2416. The safety processor 2404controls operation of the segmented circuit 2400 by activating ordeactivating the step-down converter 2416 to provide power to theremainder of the segmented circuit 2400.

FIG. 26 illustrates one aspect of a power system 2500 comprising aplurality of daisy chained power converters 2514, 2516, 2518 configuredto be sequentially energized. The plurality of daisy chained powerconverters 2514, 2516, 2518 may be sequentially activated by, forexample, a safety processor during initial power-up and/or transitionfrom sleep mode. The safety processor may be powered by an independentpower converter (not shown). For example, in one example, when a batteryvoltage VBATT is coupled to the power system 2500 and/or anaccelerometer detects movement in sleep mode, the safety processorinitiates a sequential start-up of the daisy chained power converters2514, 2516, 2518. The safety processor activates the 13V boost section2518. The boost section 2518 is energized and performs a self-check. Insome examples, the boost section 2518 comprises an integrated circuit2520 configured to boost the source voltage and to perform a self check.A diode D prevents power-up of a 5V supply section 2516 until the boostsection 2518 has completed a self-check and provided a signal to thediode D indicating that the boost section 2518 did not identify anyerrors. In some examples, this signal is provided by the safetyprocessor. The examples, however, are not limited to the particularvoltage range(s) described in the context of this specification.

The 5V supply section 2516 is sequentially powered-up after the boostsection 2518. The 5V supply section 2516 performs a self-check duringpower-up to identify any errors in the 5V supply section 2516. The 5Vsupply section 2516 comprises an integrated circuit 2515 configured toprovide a step-down voltage from the boost voltage and to perform anerror check. When no errors are detected, the 5V supply section 2516completes sequential power-up and provides an activation signal to the3.3V supply section 2514. In some examples, the safety processorprovides an activation signal to the 3.3V supply section 2514. The 3.3Vsupply section comprises an integrated circuit 2513 configured toprovide a step-down voltage from the 5V supply section 2516 and performa self-error check during power-up. When no errors are detected duringthe self-check, the 3.3V supply section 2514 provides power to theprimary processor. The primary processor is configured to sequentiallyenergize each of the remaining circuit segments. By sequentiallyenergizing the power system 2500 and/or the remainder of a segmentedcircuit, the power system 2500 reduces error risks, allows forstabilization of voltage levels before loads are applied, and preventslarge current draws from all hardware being turned on simultaneously inan uncontrolled manner. The examples, however, are not limited to theparticular voltage range(s) described in the context of thisspecification.

In one aspect, the power system 2500 comprises an over voltageidentification and mitigation circuit. The over voltage identificationand mitigation circuit is configured to detect a monopolar returncurrent in the surgical instrument and interrupt power from the powersegment when the monopolar return current is detected. The over voltageidentification and mitigation circuit is configured to identify groundfloatation of the power system. The over voltage identification andmitigation circuit comprises a metal oxide varistor. The over voltageidentification and mitigation circuit comprises at least one transientvoltage suppression diode.

FIG. 27 illustrates one aspect of a segmented circuit 2600 comprising anisolated control section 2602. The isolated control section 2602isolates control hardware of the segmented circuit 2600 from a powersection (not shown) of the segmented circuit 2600. The control section2602 comprises, for example, a primary processor 2606, a safetyprocessor (not shown), and/or additional control hardware, for example,a FET Switch 2617. The power section comprises, for example, a motor, amotor driver, and/or a plurality of motor MOSFETS. The isolated controlsection 2602 comprises a charging circuit 2603 and a rechargeablebattery 2608 coupled to a 5V power converter 2616. The charging circuit2603 and the rechargeable battery 2608 isolate the primary processor2606 from the power section. In some examples, the rechargeable battery2608 is coupled to a safety processor and any additional supporthardware. Isolating the control section 2602 from the power sectionallows the control section 2602, for example, the primary processor2606, to remain active even when main power is removed, provides afilter, through the rechargeable battery 2608, to keep noise out of thecontrol section 2602, isolates the control section 2602 from heavyswings in the battery voltage to ensure proper operation even duringheavy motor loads, and/or allows for real-time operating system (RTOS)to be used by the segmented circuit 2600. In some examples, therechargeable battery 2608 provides a stepped-down voltage to the primaryprocessor, such as, for example, 3.3V. The examples, however, are notlimited to the particular voltage range(s) described in the context ofthis specification.

FIGS. 28A and 28B illustrate another aspect of a control circuit 3000configured to control the powered surgical instrument 10, illustrated inFIGS. 1-18A. As shown in FIGS. 18A, 28B, the handle assembly 14 mayinclude a motor 3014 which can be controlled by a motor driver 3015 andcan be employed by the firing system of the surgical instrument 10. Invarious forms, the motor 3014 may be a DC brushed driving motor having amaximum rotation of, approximately, 25,000 RPM, for example. In otherarrangements, the motor 3014 may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. In certain circumstances, the motor driver 3015 maycomprise an H-Bridge FETs 3019, as illustrated in FIGS. 28A and 28B, forexample. The motor 3014 can be powered by a power assembly 3006, whichcan be releasably mounted to the handle assembly 14. The power assembly3006 is configured to supply control power to the surgical instrument10. The power assembly 3006 may comprise a battery which may include anumber of battery cells connected in series that can be used as thepower source to power the surgical instrument 10. In such configuration,the power assembly 3006 may be referred to as a battery pack. In certaincircumstances, the battery cells of the power assembly 3006 may bereplaceable and/or rechargeable. In at least one example, the batterycells can be Lithium-Ion batteries which can be separably couplable tothe power assembly 3006.

Examples of drive systems and closure systems that are suitable for usewith the surgical instrument 10 are disclosed in U.S. Provisional PatentApplication Ser. No. 61/782,866, entitled CONTROL SYSTEM OF A SURGICALINSTRUMENT, and filed Mar. 14, 2013, the entire disclosure of which isincorporated by reference herein in its entirety. For example, theelectric motor 3014 can include a rotatable shaft (not shown) that mayoperably interface with a gear reducer assembly that can be mounted inmeshing engagement with a set, or rack, of drive teeth on alongitudinally-movable drive member. In use, a voltage polarity providedby the battery can operate the electric motor 3014 to drive thelongitudinally-movable drive member to effectuate the end effector 300.For example, the motor 3014 can be configured to drive thelongitudinally-movable drive member to advance a firing mechanism tofire staples into tissue captured by the end effector 300 from a staplecartridge assembled with the end effector 300 and/or advance a cuttingmember to cut tissue captured by the end effector 300, for example.

As illustrated in FIGS. 28A and 28B and as described below in greaterdetail, the power assembly 3006 may include a power managementcontroller which can be configured to modulate the power output of thepower assembly 3006 to deliver a first power output to power the motor3014 to advance the cutting member while the interchangeable shaft 200is coupled to the handle assembly 14 (FIG. 1) and to deliver a secondpower output to power the motor 3014 to advance the cutting member whilethe interchangeable shaft assembly 200 is coupled to the handle assembly14, for example. Such modulation can be beneficial in avoidingtransmission of excessive power to the motor 3014 beyond therequirements of an interchangeable shaft assembly that is coupled to thehandle assembly 14.

In certain circumstances, the interface 3024 can facilitate transmissionof the one or more communication signals between the power managementcontroller 3016 and the shaft assembly controller 3022 by routing suchcommunication signals through a main controller 3017 residing in thehandle assembly 14 (FIG. 1), for example. In other circumstances, theinterface 3024 can facilitate a direct line of communication between thepower management controller 3016 and the shaft assembly controller 3022through the handle assembly 14 while the shaft assembly 200 (FIG. 1) andthe power assembly 3006 are coupled to the handle assembly 14.

In one instance, the main microcontroller 3017 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one instance, the surgical instrument 10 (FIGS.1-4) may comprise a power management controller 3016 such as, forexample, a safety microcontroller platform comprising twomicrocontroller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments.Nevertheless, other suitable substitutes for microcontrollers and safetyprocessor may be employed, without limitation. In one instance, thesafety processor 2004 (FIG. 21A) may be configured specifically for IEC61508 and ISO 26262 safety critical applications, among others, toprovide advanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

In certain instances, the microcontroller 3017 may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

FIG. 29 is a block diagram the surgical instrument of FIG. 1illustrating interfaces between the handle assembly 14 (FIG. 1) and thepower assembly and between the handle assembly 14 and theinterchangeable shaft assembly. As shown in FIG. 29, the power assembly3006 may include a power management circuit 3034 which may comprise thepower management controller 3016, a power modulator 3038, and a currentsense circuit 3036. The power management circuit 3034 can be configuredto modulate power output of the battery 3007 based on the powerrequirements of the shaft assembly 200 (FIG. 1) while the shaft assembly200 and the power assembly 3006 are coupled to the handle assembly 14.For example, the power management controller 3016 can be programmed tocontrol the power modulator 3038 of the power output of the powerassembly 3006 and the current sense circuit 3036 can be employed tomonitor power output of the power assembly 3006 to provide feedback tothe power management controller 3016 about the power output of thebattery 3007 so that the power management controller 3016 may adjust thepower output of the power assembly 3006 to maintain a desired output.

It is noteworthy that the power management controller 3016 and/or theshaft assembly controller 3022 each may comprise one or more processorsand/or memory units which may store a number of software modules.Although certain modules and/or blocks of the surgical instrument 14(FIG. 1) may be described by way of example, it can be appreciated thata greater or lesser number of modules and/or blocks may be used.Further, although various instances may be described in terms of modulesand/or blocks to facilitate description, such modules and/or blocks maybe implemented by one or more hardware components, e.g., processors,Digital Signal Processors (DSPs), Programmable Logic Devices (PLDs),Application Specific Integrated Circuits (ASICs), circuits, registersand/or software components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components.

In certain instances, the surgical instrument 10 (FIGS. 1-4) maycomprise an output device 3042 which may include one or more devices forproviding a sensory feedback to a user. Such devices may comprise, forexample, visual feedback devices (e.g., an LCD display screen, LEDindicators), audio feedback devices (e.g., a speaker, a buzzer) ortactile feedback devices (e.g., haptic actuators). In certaincircumstances, the output device 3042 may comprise a display 3043 whichmay be included in the handle assembly 14 (FIG. 1). The shaft assemblycontroller 3022 and/or the power management controller 3016 can providefeedback to a user of the surgical instrument 10 through the outputdevice 3042. The interface 3024 can be configured to connect the shaftassembly controller 3022 and/or the power management controller 3016 tothe output device 3042. The reader will appreciate that the outputdevice 3042 can instead be integrated with the power assembly 3006. Insuch circumstances, communication between the output device 3042 and theshaft assembly controller 3022 may be accomplished through the interface3024 while the shaft assembly 200 is coupled to the handle assembly 14.

Having described a surgical instrument 10 (FIGS. 1-4) and variouscontrol circuits 2000, 3000 for controlling the operation thereof, thedisclosure now turns to various specific configurations of the surgicalinstrument 10 and control circuits 2000 (or 3000).

The present disclosure provides additional techniques to overcomechallenges with conventional modular endosurgical devices. Two of thesetechniques, in the context of modular endocutters, include wire contactsto transmit power and receive signals from an end effector shaftconfigured to rotate, and the ability to upgrade the modular attachmentwith new tech and sensors while allowing the handle to readily acceptthe new tech.

The ability for the sensors in the end-effector to have the signalprocessing capability built into the sensor itself helps improve both ofthese issues. In one aspect, the sensor can be configured to supply thehandle with processed information rather than supplying the handle withraw data to minimize the impact of newer sensors and the number of wiresnecessary to run them. In one aspect, a series of smart sensors can beplaced in parallel along a single power line with the shaft of thedevice as the return path and using current draw “signal” the handle tostop, or start, or end etc. In accordance with this technique, thehandle does not need to know what the sensor actually is or how tointerpret the processed information being fed back to the controller.Likewise, the current draw can be monitored using a standard Morse Codelike encoding technique on the power line to enable the handle to knowwhat the issue is and which sensor identified the issue without anypairing or other couple communication requirement.

Medical devices may be modular devices that include several separatecomponents. For example, an endocutter such as endocutter 12010 as shownin FIG. 30 may include several large and small separate components. Theendocutter 12010 is similarly constructed and equipped as themotor-driven surgical cutting and fastening instrument 10 described inconnection with FIGS. 1-29. Accordingly, for conciseness and clarity thedetails of operation and construction will not be repeated here.Endocutter 12010 may include a handle component 12012, a shaft component12014, and an end-effector component 12016. Each of the handle, theshaft, and the end-effector may include smaller but separate componentssuch as sensors, transducers, motors, switches, controllers, processorsetc., which may be programmable and interoperable with one another. Inthis way, endocutter 12010 may be a modular medical device.

In general, modular devices may have several challenges to overcome. Forexample, modular endocutter 12010 may require multiple wire contactsconfigured to transmit power and receive signals. A power source, suchas a battery 90 (FIG. 4), may transfer power to one or more sensors,transducers, motors, switches, controllers, processors, or other modularcomponents of the endocutter through various wires and wire contacts.One or more of these modular components may receive signals from oneanother in order to perform various calculations, processes, or actionsto operate the endocutter. For example, a sensor in end-effector 12016may be powered from a battery in handle 12012 through a wire in shaft12014 and may send back signals or data to a microprocessor ormicrocontroller in handle 12012 through a different wire in shaft 12014.The shaft 12014 may be only a half inch in diameter and may have theability to rotate, which may lead to challenges when swapping orupgrading modular components such as sensors.

In some systems, a sensor in the end-effector may send data to thehandle. The data may require signal processing or other processing byone or more components in the handle in order to be used to operate theendocutter. Adding a new sensor or upgrading an existing sensor mayrequire new wires to enable communication with the one or morecomponents (e.g., a microprocessor) in the handle. Having to add newwires or wire contacts may negatively impact the ability to use newsensors or upgrade existing sensors and may be undesirable. The abilityto upgrade the modular components (e.g., sensors) in, for example, theend-effector 12016, with new technology such as more advanced sensors,while allowing components in the handle 12012 (e.g., a microcontroller12024) to readily accept output from the new sensors without adding newwires or new wire contacts may be desirable.

In one aspect of the present disclosure, one or more sensors in theend-effector (e.g., end-effector 12016) may have local or built-insignal processing capability. These sensors may be referred to as smartsensors. Rather than supplying the handle or one or more componentstherein with data that may require further processing, smart sensorswith local signal processing may supply the handle with alreadyprocessed data or information that can be used to operate the endocutterwhile minimizing or eliminating further processing.

For example, the end-effector 12016 may include a sensor 12020 andsignal processing component 12022. The signal processing component 12022may correspond to the sensor 12020 (i.e., may be configured to processdata from sensor 12020). In one example, the signal processing component12022 may be specially designed or configured to process signals or datareceived from the sensor 12020. Further, the signal processing component12022 may generate processed information based on the signals or datareceived from sensor 12020. In this way, the signal processing component12022 may process data received from the sensor 12020 of a surgicalinstrument (i.e., the endocutter 12010) locally to the sensor and intoinformation usable by the surgical instrument.

The handle 12012 (or a component therein) may be configured to receivethe processed information from the signal processing component 12022.For example, the signal processing component 12022 may transmit theprocessed information to handle 12012 via shaft 12014 (through, e.g.,one or more wires). In this way, the processed information may betransmitted from the signal processing component 12022 to a controller12024 (e.g., a microcontroller) of the surgical instrument (e.g., theendocutter 12010). Further, the surgical instrument (e.g., theendocutter 12010) may be controlled based on the processed informationfrom the signal processing component 12022. For example, theend-effector 12016 may be stopped or started or a process of theendocutter 12010 may be ended based on the processed information. In oneexample, the controller 12024 may stop or start the end-effector basedon the processed information.

The signal processing component 12022 and the sensor 12020 may be partof a single module 12018. The single module 12018 may be positioned inthe end-effector 12016 and may be a modular component easily swappedinto or out of the end-effector 12016. The sensor 12020 may be, forexample, a magnetic field sensor, a magnetic sensor, an inductivesensor, a capacitive sensor, or another type of sensor used in medicaldevices or endocutters. The signal processing component 12022 may be themicrocontroller 2006 (FIGS. 21A, 21B) or microcontroller 3017 (FIGS.28A, 28B).

In one aspect, the signal processing component may be a sensor circuit12036 as shown in FIG. 31. The sensor circuit 12036 may be any suitablecircuit configured to read signals from a sensor component such as aninductive coil 12032. The sensor circuit 12036 may be in communicationwith or be communicatively coupled to a sensor component in theend-effector 12030. For example, the sensor circuit 12036 may becommunicatively coupled to an inductive coil 12032 via a wire or cable12038. The inductive coil 12032 may produce a magnetic field 12034 andmay be located at a distal end of an anvil 12040 of the end-effector12030. The sensor circuit 12036 may receive data or signals from thesensor component (e.g., inductive coil 12032) and may process the dataor signals to generate processed information which may be used tooperate the end-effector 12030.

While the sensor circuit 12036 is shown outside of the end-effector12030 and the anvil 12040 in FIG. 31 for ease of disclosure, the sensorcircuit 12036 may be local to the sensor component (e.g., inductive coil12032) or may be part of a single module including the sensor componentand the sensor circuit, such as single module 12018 of FIG. 30. Forexample, as shown in FIG. 32, a sensor circuit 12052 also may bepositioned at a distal end of an anvil 12056 of an end-effector 12050.The sensor circuit 12052 may be local to, and in communication with, asensing component such as magnet 12054.

Referring back to FIG. 30, the handle 12012 may include a controller12024 which may be configured to control or otherwise operate theendocutter 12010. In one example, the controller 12012 may be amicrocontroller and may be configured to receive the processedinformation from the signal processing component 12022 or the singlemodule 12018. For example the shaft 12014 may be configured tocommunicatively couple the signal processing component 12022 of theend-effector 12016 and the handle 12012. The microcontroller 12024 inthe handle 12012 may be in wired communication with the signalprocessing component 12022 via shaft 12014. In one example, the signalprocessing component 12022 may be in wireless communication with themicrocontroller 12024 or with another component in handle 12012. Whilethe controller 12024 may be configured to receive the processedinformation from the signal processing component 12022 or the singlemodule 12018, this is not intended to be a limitation of the presentdisclosure as various other components (e.g., a microprocessor, display,interface, switch, etc.) in handle 12012 may be configured to receivethe processed information from the signal processing component 12022 orthe single module 12018.

In one aspect, a plurality of smart sensors may be positioned on a powerline of an end-effector and may be communicatively coupled to a handleof an endocutter. The smart sensors may be positioned in series orparallel with respect to the power line. Referring now to FIG. 33, smartsensors 12060 and 12062 may be in communication with a signal processingcomponent or a microprocessor 12064 which may be local to the smartsensors. Both the smart sensors 12060 and 12062 and the microprocessor12064 may be located at the end-effector (represented by dashed-box12066). For example, smart sensor 12060 may output signals or data to anoperational amplifier 12068 and an ADC converter 12070, which maycondition the signals or data for input into microprocessor 12064.Similarly, smart sensor 12062 may output signals or data to anoperational amplifier 12072 and an ADC converter 12074, which maycondition the signals or data for input into microprocessor 12064.

Smart sensors 12060 and/or 12062 may be different types of sensors orthe same type of sensor, which may be, for example, magnetic fieldsensors, magnetic sensors, inductive sensors, capacitive sensors, orother types of sensors used in medical devices or endocutters. Component12064, previously referred to as a microprocessor, also may be acomputational core, FPGA (field programmable gate array), logic unit(e.g., logic processor or logic controller), signal processing unit, orother type of processor. The microprocessor 12064 may be incommunication with a memory, such as non-volatile memory 12076, whichmay store calculation data, equipment information such as a type ofcartridge inserted in the end-effector 12066, tabular data, or otherreference data that may enable the microprocessor 12064 to processsignals or data received from one or more of the smart sensors 12060 or12062 for use in operating the end-effector 12066 or an endocutter.

Further, a shaft 12078 may include a return path through which at leastone of the plurality of smart sensors (e.g., smart sensors 12060 or12062) and the handle 12080 are communicatively coupled. The shaft mayinclude one or more wires which may transfer information from themicroprocessor 12064 to the handle 12080 for operation of theend-effector 12066 or endocutter. In one example, the information fromthe microprocessor 12064 may be communicated to the handle 12080 (by wayof shaft 12078 or directly without use of shaft 12078) over one or moreof: a wired-line, a single-wired line, a multi-wired line, a wirelesscommunication protocol such as Bluetooth, an optical line, or anacoustic line.

In one aspect, at least one of a plurality of smart sensors positionedat an end-effector may include a signal processing component. Forexample, the signal processing component may be built into the smartsensor or may be locally coupled to the smart sensor as shown in singlemodule 12018 of FIG. 30. The signal processing component may beconfigured to process data received from a sensor component (e.g.,sensor component 12020) of at least one of the plurality of smartsensors. A controller 12024 (e.g., a microcontroller) at the handle maybe communicatively coupled to at least one of the plurality of smartsensors.

In one aspect, a smart sensor may be configured for local signalprocessing in a medical device. The smart sensor may include at leastone sensor component (e.g., sensor component 12020) and at least oneprocessing component (e.g., processing component 12022). The processingcomponent may be configured to receive data from the at least one sensorcomponent and to process the data into information for use by themedical device. The medical device may be, for example, an endocutter,however this is not intended to be a limitation of the presentdisclosure. It should be understood that the techniques and featuresdiscussed herein for smart sensors with local signal processing may beused in any medical device where processing of sensor signals or data isused for operation of the medical device.

Further, a controller (e.g., controller 12024, microcontroller) in themedical device may be configured to receive the information (i.e.,processed signals or data) from the at least one processing component(e.g., processing component 12022). As discussed above, the medicaldevice may be a surgical instrument such as an endocutter and the smartsensor may be configured for local signal processing in the surgicalinstrument. Local signal processing may refer to, for example,processing signals or data from a sensor component at a processingcomponent coupled to the sensor, where the resulting processedinformation may be used by a separate component. For example, thecontroller 12024 may be positioned in the handle 12012 of the surgicalinstrument (i.e., the endocutter 12010) and the smart sensor may beconfigured to be positioned in a separate component (i.e., theend-effector 12016) of the surgical instrument (i.e., the endocutter12010), separate from the handle 12012. Thus, the controller 12024 maybe positioned at the handle 12012 of the surgical instrument and thesignal processing component 12022 and the sensor 12020 may be located ina component separate from the handle 12012 (e.g., end-effector 12016).

In this way, the handle or controller 12024 need not have informationabout the smart sensor, knowledge of what the smart sensor is doing, orcapability to interpret data feed back from the smart sensor. This isbecause the processing component 12022 may transform or condition thedata from the smart sensor and generate information from the datadirectly usable by the handle or controller 12024. The informationgenerated by the processing component may be used directly, without thedata from the smart sensor needing to be processed in another part ofthe medical device (e.g., near the handle 12012 or controller 12024).Thus, the surgical instrument may be controlled based on the (processed)information from the signal processing component local to the sensor.

In one aspect, a current draw on a power line communicatively coupled tothe signal processing component 12022 (i.e., local to the sensor 12020)may be monitored. The current draw may be monitored by a microprocessoror other monitoring device at the shaft 12014 or the handle 12012, or atanother microprocessor or other monitoring device separate from thesignal processing component 12022. For example, the monitoring may be astandard Morse Code type monitoring of the current draw on the powerline. An issue with the surgical instrument based on the current drawand a particular sensor may be determined by the separate microprocessorat, e.g., the handle 12012. In this way, the monitoring may allow thehandle (or a processor or controller therein) to be informed of variousissues related to signals or data received by one or more sensor andwhich particular sensor identified the issue, without a furthercommunication requirement (e.g., pairing, or other coupledcommunication).

Turning now to FIG. 34, which is a logic diagram illustrating one aspectof a process 13040 for calibrating a first sensor 13008 a in response toan input from a second sensor 13008 b. The first sensor 13008 a isconfigured to capture 13022 a a signal indicative of one or moreparameters of the end effector 13000. The first signal 13022 a may beconditioned based on one or more predetermined parameters, such as, forexample, a smoothing function, a look-up table, and/or any othersuitable conditioning parameters. A second signal is captured 13022 b bythe second sensor 13008 b. The second signal 13022 b may be conditionedbased on one or more predetermined conditioning parameters. The firstsignal 13022 a and the second signal 13022 b are provided to aprocessor, such as, for example, the primary processor 2006 (FIGS.21A-21B). The primary processor 2006 calibrates 13042 the first signal13022 a in response to the second signal 13022 b. The first signal 13022a is calibrated 13042 to reflect the fullness of the bite of tissue inthe end effector 13000. The calibrated signal is displayed 13026 to anoperator by, for example, a display 12026 embedded in the surgicalinstrument 10 (FIGS. 1-6).

FIG. 35 is a logic diagram illustrating one aspect of a process 13170for adjusting a measurement of a first sensor 13158 in response to aplurality of secondary sensors 13160 a, 13160. In one example, a Halleffect voltage is obtained 13172, for example, by a magnetic fieldsensor. The Hall effect voltage is converted 13174 by an analog todigital convertor. The converted Hall effect voltage signal iscalibrated 13176. The calibrated curve represents the thickness of atissue section located between the anvil 13152 and the staple cartridge13156. A plurality of secondary measurements are obtained 13178 a, 13178b by a plurality of secondary sensors, such as, for example, a pluralityof strain gauges. The input of the strain gauges is converted 13180 a,13180 b into one or more digital signals, for example, by a plurality ofelectronic μStrain conversion circuits. The calibrated Hall effectvoltage and the plurality of secondary measurements are provided to aprocessor, such as, for example, the primary processor 2006 (FIGS.21A-21B). The primary processor utilizes the secondary measurements toadjust 13182 the Hall effect voltage, for example, by applying analgorithm and/or utilizing one or more look-up tables. The adjusted Halleffect voltage represents the true thickness and fullness of the bite oftissue clamped by the anvil 13152 and the staple cartridge 13156. Theadjusted thickness is displayed 13026 to an operator by, for example, adisplay 12026 embedded in the surgical instrument 10 (FIGS. 1-6).

FIG. 36 illustrates one aspect of a circuit 13190 configured to convertsignals from the first sensor 13158 and the plurality of secondarysensors 13160 a, 13160 b into digital signals receivable by a processor,such as, for example, the primary processor 2006 (FIGS. 21A-21B). Thecircuit 13190 comprises an analog-to-digital convertor 13194. In someexamples, the analog-to-digital convertor 13194 comprises a 4-channel,18-bit analog to digital convertor. Those skilled in the art willrecognize that the analog-to-digital convertor 13194 may comprise anysuitable number of channels and/or bits to convert one or more inputsfrom analog to digital signals. The circuit 13190 comprises one or morelevel shifting resistors 13196 configured to receive an input from thefirst sensor 13158, such as, for example, a magnetic field sensor. Thelevel shifting resistors 13196 adjust the input from the first sensor,shifting the value to a higher or lower voltage depending on the input.The level shifting resistors 13196 provide the level-shifted input fromthe first sensor 13158 to the analog-to-digital convertor.

In some aspects, a plurality of secondary sensors 13160 a, 13160 b arecoupled to a plurality of bridges 13192 a, 13192 b within the circuit13190. The plurality of bridges 13192 a, 13192 b may provide filteringof the input from the plurality of secondary sensors 13160 a, 13160 b.After filtering the input signals, the plurality of bridges 13192 a,13192 b provide the inputs from the plurality of secondary sensors 13160a, 13160 b to the analog-to-digital convertor 13194. In some examples, aswitch 13198 coupled to one or more level shifting resistors may becoupled to the analog-to-digital convertor 13194. The switch 13198 isconfigured to calibrate one or more of the input signals, such as, forexample, an input from a magnetic field sensor. The switch 13198 may beengaged to provide one or more level shifting signals to adjust theinput of one or more of the sensors, such as, for example, to calibratethe input of a magnetic field sensor. In some examples, the adjustmentis not necessary, and the switch 13198 is left in the open position todecouple the level shifting resistors. The switch 13198 is coupled tothe analog-to-digital convertor 13194. The analog-to-digital convertor13194 provides an output to one or more processors, such as, forexample, the primary processor 2006 (FIGS. 21A-21B). The primaryprocessor 2006 calculates one or more parameters of the end effector13150 based on the input from the analog-to-digital convertor 13194. Forexample, in one example, the primary processor 2006 calculates athickness of tissue located between the anvil 13152 and the staplecartridge 13156 based on input from one or more sensors 13158, 13160 a,13160 b.

FIG. 37 is a logic diagram illustrating one aspect of a process 13320for selecting the most reliable output from a plurality of redundantsensors, such as, for example, the plurality of sensors 13308 a, 13308b. In one example, a first signal is generated by a first sensor 13308a. The first signal is converted 13322 a by an analog-to-digitalconvertor. One or more additional signals are generated by one or moreredundant sensors 13308 b. The one or more additional signals areconverted 13322 b by an analog-to-digital convertor. The convertedsignals are provided to a processor, such as, for example, the primaryprocessor 2006 (FIGS. 21A-21B). The primary processor 2006 evaluates13324 the redundant inputs to determine the most reliable output. Themost reliable output may be selected based on one or more parameters,such as, for example, algorithms, look-up tables, input from additionalsensors, and/or instrument conditions. After selecting the most reliableoutput, the processor may adjust the output based on one or moreadditional sensors to reflect, for example, the true thickness and biteof a tissue section located between the anvil 13302 and the staplecartridge 13306. The adjusted most reliable output is displayed 13026 toan operator by, for example, a display 2026 embedded in the surgicalinstrument 10 (FIGS. 1-6).

FIG. 38 illustrates one aspect of an end effector 13000 comprising amagnet 13008 and a magnetic field sensor 13010 in communication with aprocessor 13012. The end effector 13000 is similar to the end effector300 (FIG. 1) described above in connection with surgical instrument 10(FIGS. 1-6). The end effector 13000 comprises a first jaw member, oranvil 13002, pivotally coupled to a second jaw member, or elongatedchannel 13004. The elongated channel 13004 is configured to operablysupport a staple cartridge 13006 therein. The staple cartridge 13006 issimilar to the staple cartridge 304 (FIG. 1) described above inconnection with surgical instrument 10 (FIGS. 1-6). The anvil 13008comprises a magnet 13008. The staple cartridge comprises a magneticfield sensor 13010 and a processor 13012. The magnetic field sensor13010 is operable to communicate with the processor 13012 through aconductive coupling 13014. The magnetic field sensor 13010 is positionedwithin the staple cartridge 13006 to operatively couple with the magnet13008 when the anvil 13002 is in a closed position. The magnetic fieldsensor 13010 can be configured to detect changes in the magnetic fieldsurrounding the magnetic field sensor 13010 caused by the movement of orlocation of magnet 13008.

FIGS. 39-41 illustrate one aspect of an end effector that comprises amagnet where FIG. 39 illustrates a perspective cutaway view of the anvil13102 and the magnet 13058 a, in an optional location. FIG. 40illustrates a side cutaway view of the anvil 13102 and the magnet 13058a, in an optional location. FIG. 41 illustrates a top cutaway view ofthe anvil 13102 and the magnet 13058 a, in an optional location.

FIG. 42 illustrates one aspect of an end effector 13200 that is operableto use conductive surfaces at the distal contact point to create anelectrical connection. The end effector 13200 is similar to the endeffector 300 (FIG. 1) described above in connection with surgicalinstrument 10 (FIGS. 1-6). The end effector 13200 comprises an anvil13202, an elongated channel 13204, and a staple cartridge 13206. Theanvil 13202 further comprises a magnet 13208 and an inside surface13210, which further comprises a number of staple-forming indents 13212.In some examples, the inside surface 13210 of the anvil 13202 furthercomprises a first conductive surface 13214 surrounding thestaple-forming indents 13212. The first conductive surface 13214 cancome into contact with second conductive surfaces 13222 on the staplecartridge 13206. The cartridge body comprises a number of staplecavities designed to hold staples (not pictured). In some examples thestaple cavities further comprise staple cavity extensions that protrudeabove the surface of the cartridge body. The staple cavity extensionscan be coated with the second conductive surfaces. Because the staplecavity extensions protrude above the surface of the cartridge body, thesecond conductive surfaces will come into contact with the firstconductive surfaces 13214 when the anvil 13202 is in a closed position.In this manner the anvil 13202 can form an electrical contact with thestaple cartridge 13206.

FIG. 43 illustrates one aspect of a staple cartridge 13606 thatcomprises a flex cable 13630 connected to a magnetic field sensor 13610and processor 13612. The staple cartridge 13606 is similar to the staplecartridge 13606 is similar to the staple cartridge 306 (FIG. 1)described above in connection with surgical instrument 10 (FIGS. 1-6).FIG. 43 is an exploded view of the staple cartridge 13606. The staplecartridge comprises 13606 a cartridge body 13620, a wedge sled 13618, acartridge tray 13622, and a flex cable 13630. The flex cable 13630further comprises electrical contacts 13632 at the proximal end of thestaple cartridge 13606, placed to make an electrical connection when thestaple cartridge 13606 is operatively coupled with an end effector, suchas end effector 13800 described below. The electrical contacts 13632 areintegrated with cable traces 13634, which extend along some of thelength of the staple cartridge 13606. The cable traces 13634 connect13636 near the distal end of the staple cartridge 13606 and thisconnection 13636 joins with a conductive coupling 13614. A magneticfield sensor 13610 and a processor 13612 are operatively coupled to theconductive coupling 13614 such that the magnetic field sensor 13610 andthe processor 13612 are able to communicate.

FIG. 44 illustrates one aspect of an end effector 13800 with a flexcable 13830 operable to provide power to a staple cartridge 13806 thatcomprises a distal sensor plug 13816. The end effector 13800 is similarto the end effector 300 (FIG. 1) described above in connection withsurgical instrument 10 (FIGS. 1-6). The end effector 13800 comprises afirst jaw member or anvil 13802, a second jaw member or elongatedchannel 13804, and a staple cartridge 13806 operatively coupled to theelongated channel 13804. The end effector 13800 is operatively coupledto a shaft assembly. The shaft assembly is similar to shaft assembly 200(FIG. 1) described above in connection with surgical instrument 10(FIGS. 1-6). The shaft assembly further comprises a closure tube thatencloses the exterior of the shaft assembly. In some examples the shaftassembly further comprises an articulation joint 13904, which includes adouble pivot closure sleeve assembly. The double pivot closure sleeveassembly includes an end effector closure sleeve assembly that isoperable to couple with the end effector 13800.

FIGS. 45 and 46 illustrate the elongated channel 13804 portion of theend effector 13800 without the anvil 13802 or the staple cartridge, toillustrate how the flex cable 13830 can be seated within the elongatedchannel 13804. In some examples, the elongated channel 13804 furthercomprises a third aperture 13824 for receiving the flex cable 13830.Within the body of the elongated channel 13804 the flex cable splits13834 to form extensions 13836 on either side of the elongated channel13804. FIG. 46 further illustrates that connectors 13838 can beoperatively coupled to the flex cable extensions 13836.

FIG. 47 illustrates the flex cable 13830 alone. As illustrated, the flexcable 13830 comprises a single coil 13832 operative to wrap around thearticulation joint 13904 (FIG. 44), and a split 13834 that attaches toextensions 13836. The extensions can be coupled to connectors 13838 thathave on their distal facing surfaces prongs 13840 for coupling to thestaple cartridge 13806, as described below.

FIG. 48 illustrates a close up view of the elongated channel 13804 shownin FIGS. 45 and 115 with a staple cartridge 13804 coupled thereto. Thestaple cartridge 13804 comprises a cartridge body 13822 and a cartridgetray 13820. In some examples the staple cartridge 13806 furthercomprises electrical traces 13828 that are coupled to proximal contacts13856 at the proximal end of the staple cartridge 13806. The proximalcontacts 13856 can be positioned to form a conductive connection withthe prongs 13840 of the connectors 13838 that are coupled to the flexcable extensions 13836. Thus, when the staple cartridge 13806 isoperatively coupled with the elongated channel 13804, the flex cable13830, through the connectors 13838 and the connector prongs 13840, canprovide power to the staple cartridge 13806.

FIGS. 49 and 50 illustrate one aspect of a distal sensor plug 13816.FIG. 49 illustrates a cutaway view of the distal sensor plug 13816. Asillustrated, the distal sensor plug 13816 comprises a magnetic fieldsensor 13810 and a processor 13812. The distal sensor plug 13816 furthercomprises a flex board 13814. As further illustrated in FIG. 50, themagnetic field sensor 13810 and the processor 13812 are operativelycoupled to the flex board 13814 such that they are capable ofcommunicating.

FIG. 51 illustrates one aspect of an end effector 13950 with a flexcable 13980 operable to provide power to sensors and electronics in thedistal tip 13952 of the anvil 13961 portion. The end effector 13950comprises a first jaw member or anvil 13961, a second jaw member orelongated channel 13954, and a staple cartridge 13956 operativelycoupled to the elongated channel. The end effector 13950 is operativelycoupled to a shaft assembly 13960. The shaft assembly 13960 furthercomprises a closure tube 13962 that encloses the shaft assembly 13960.In some examples the shaft assembly 13960 further comprises anarticulation joint 13964, which includes a double pivot closure sleeveassembly 13966.

In various aspects, the end effector 13950 further comprises a flexcable 13980 that is configured to not interfere with the function of thearticulation joint 13964. In some examples, the closure tube 13962comprises a first aperture 13968 through which the flex cable 13980 canextend. In some examples, flex cable 13980 further comprises a loop orcoil 13982 that wraps around the articulation joint 13964 such that theflex cable 13980 does not interfere with the operation of thearticulation joint 13964, as further described below. In some examples,the flex cable 13980 extends along the length of the anvil 13961 to asecond aperture 13970 in the distal tip of the anvil 13961.

FIGS. 52-54 illustrate the operation of the articulation joint 13964 andflex cable 13980 of the end effector 13950. FIG. 52 illustrates a topview of the end effector 13952 with the end effector 13950 pivoted −45degrees with respect to the shaft assembly 13960. As illustrated, thecoil 13982 of the flex cable 13980 flexes with the articulation joint13964 such that the flex cable 13980 does not interfere with theoperation of the articulation joint 13964. FIG. 53 illustrates a topview of the end effector 13950. As illustrated, the coil 13982 wrapsaround the articulation joint 13964 once. FIG. 54 illustrates a top viewof the end effector 13950 with the end effector 13950 pivoted +45degrees with respect to the shaft assembly 13960. As illustrated, thecoil 13982 of the flex cable 13980 flexes with the articulation joint13964 such that the flex cable 13980 does not interfere with theoperation of the articulation joint 13964.

FIG. 55 illustrates cross-sectional view of the distal tip of one aspectof an anvil 13961 with sensors and electronics 13972. The anvil 13961comprises a flex cable 13980, as described with respect to FIGS. 52-54.As illustrated in FIG. 55, the anvil 13961 further comprises a secondaperture 13970 through which the flex cable 13980 can pass such that theflex cable 13980 can enter a housing 13974 in the within the anvil13961. Within the housing 13974 the flex cable 13980 can operably coupleto sensors and electronics 13972 located within the housing 13974 andthereby provide power to the sensors and electronics 13972.

FIG. 56 illustrates a cutaway view of the distal tip of the anvil 13961.FIG. 56 illustrates one aspect of the housing 13974 that can containsensors and electronics 13972 as illustrated by FIG. 55.

The present disclosure will now be described in connection with variousexamples and combinations of such examples as set forth hereinbelow.

1. One example provides a device comprising: an end-effector includingat least one sensor and a signal processing component corresponding tothe at least one sensor; and a handle configured to receive processedinformation from the signal processing component; wherein the processedinformation is generated by the signal processing component at theend-effector based on data received from the at least one sensor at theend-effector.

2. Another example provides the device of example 1, wherein the signalprocessing component and the sensor are part of a single module at theend-effector.

3. Another example provides the device of example 1 or 2, wherein theprocessed information is received by a controller at the handle.

4. Another example provides the device of any one of examples 1-3,further comprising: a shaft configured to communicatively couple thesignal processing component of the end-effector and the handle.

5. Another example provides the device of any one of examples 1-4,wherein the signal processing component is a sensor circuit.

6. Yet another example provides a device comprising: a plurality ofsmart sensors positioned on a power line of an end-effector andcommunicatively coupled to a handle; and a shaft including a return paththrough which at least one of the plurality of smart sensors and thehandle are communicatively coupled.

7. Another example provides the device of example 6, wherein at leastone of the plurality of smart sensors includes a signal processingcomponent configured to process data received from a sensor component ofat least one of the plurality of smart sensors.

8. Another example provides the device of example 6 or 7, furthercomprising: a controller at the handle to which at least one of theplurality of smart sensors is commutatively coupled.

9. Yet another example provides a smart sensor configured for localsignal processing in a medical device, the smart sensor comprising: atleast one sensor component; at least one processing component configuredto receive data from the at least one sensor component and to processthe data into information for use by the medical device; and acontroller in the medical device configured to receive the informationfrom the at least one processing component.

10. Another example provides the smart sensor of example 9, wherein themedical device is a surgical instrument and the smart sensor isconfigured for local signal processing in the surgical instrument.

11. Another example provides the smart sensor of example 9 or 10,wherein the controller is positioned in a handle of the surgicalinstrument and the smart sensor is configured to be positioned in acomponent of the surgical instrument separate from the handle.

12. Yet another example provides a method for controlling a surgicalinstrument, the method comprising: processing data received from asensor of the surgical instrument, at a signal processing componentlocal to the sensor, into information usable by the surgical instrument;and transmitting the information from the signal processing component toa controller of the surgical instrument.

13. Another example provides the method of example 12, furthercomprising: controlling the surgical instrument based on the informationfrom the signal processing component.

14. Another example provides the method of example 12 or 13, furthercomprising: monitoring a current draw on a power line communicativelycoupled to the signal processing component local to the sensor; anddetermining an issue with the surgical instrument based on the currentdraw and the sensor.

15. Another example provides the method of any one of examples 12-14,wherein the sensor and the signal processing component are part of asingle module.

16. Another example provides the method of any one of examples 12-15,wherein the controller is positioned at a handle of the surgicalinstrument and the signal processing component and the sensor arelocated in a component separate from the handle.

In accordance with various examples, the surgical instruments describedherein may comprise one or more processors (e.g., microprocessor,microcontroller) coupled to various sensors. In addition, to theprocessor(s), a storage (having operating logic) and communicationinterface, are coupled to each other.

As described earlier, the sensors may be configured to detect andcollect data associated with the surgical device. The processorprocesses the sensor data received from the sensor(s).

The processor may be configured to execute the operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various aspects, the operating logic may be configured to perform theinitial processing, and transmit the data to the computer hosting theapplication to determine and generate instructions. For these examples,the operating logic may be further configured to receive informationfrom and provide feedback to a hosting computer. In alternate examples,the operating logic may be configured to assume a larger role inreceiving information and determining the feedback. In either case,whether determined on its own or responsive to instructions from ahosting computer, the operating logic may be further configured tocontrol and provide feedback to the user.

In various aspects, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other examples, theoperating logic may be implemented in hardware such as a gate array.

In various aspects, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various examples, the communication interface maybe a wired or a wireless communication interface. An example of a wiredcommunication interface may include, but is not limited to, a UniversalSerial Bus (USB) interface. An example of a wireless communicationinterface may include, but is not limited to, a Bluetooth interface.

For various aspects, the processor may be packaged together with theoperating logic. In various examples, the processor may be packagedtogether with the operating logic to form a SiP. In various examples,the processor may be integrated on the same die with the operatinglogic. In various examples, the processor may be packaged together withthe operating logic to form a System on Chip (SoC).

Various aspects may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some examples also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some aspects may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other examples, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, ASICs, PLDs, DSPs, FPGAs, logic gates,registers, semiconductor device, chips, microchips, chip sets, and soforth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether one example is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application APIs, and so forth. The firmware may be stored in amemory of the controller and/or the controller which may comprise anonvolatile memory (NVM), such as in bit-masked ROM or flash memory. Invarious implementations, storing the firmware in ROM may preserve flashmemory. The NVM may comprise other types of memory including, forexample, programmable ROM (PROM), erasable programmable ROM (EPROM),EEPROM, or battery backed RAM such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various aspects may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more examples. In variousexamples, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The examples,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with the examplesdisclosed herein may be implemented in the general context of computerexecutable instructions, such as software, control modules, logic,and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some examples also may be practiced indistributed computing environments where operations are performed by oneor more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the aspects described hereinillustrate example implementations, and that the functional elements,logical blocks, modules, and circuits elements may be implemented invarious other ways which are consistent with the described examples.Furthermore, the operations performed by such functional elements,logical blocks, modules, and circuits elements may be combined and/orseparated for a given implementation and may be performed by a greaternumber or fewer number of components or modules. As will be apparent tothose of skill in the art upon reading the present disclosure, each ofthe individual examples described and illustrated herein has discretecomponents and features which may be readily separated from or combinedwith the features of any of the other several aspects without departingfrom the scope of the present disclosure. Any recited method can becarried out in the order of events recited or in any other order whichis logically possible.

It is worthy to note that any reference to “one example” or “an example”means that a particular feature, structure, or characteristic describedin connection with the example is comprised in at least one example. Theappearances of the phrase “in one example” or “in one aspect” in thespecification are not necessarily all referring to the same example.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some aspects may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someaspects may be described using the terms “connected” and/or “coupled” toindicate that two or more elements are in direct physical or electricalcontact with each other. The term “coupled,” however, also may mean thattwo or more elements are not in direct contact with each other, but yetstill co-operate or interact with each other. With respect to softwareelements, for example, the term “coupled” may refer to interfaces,message interfaces, API, exchanging messages, and so forth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The present disclosure applies to conventional endoscopic and opensurgical instrumentation as well as application in robotic-assistedsurgery.

Aspects of the devices disclosed herein can be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Examples may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, examples of the device may be disassembled, and any numberof the particular pieces or parts of the device may be selectivelyreplaced or removed in any combination. Upon cleaning and/or replacementof particular parts, examples of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a surgicalteam immediately prior to a surgical procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, aspects described herein may be processed beforesurgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device also may be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, plasma peroxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated can also be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically matable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing disclosure hasbeen presented for purposes of illustration and description. It is notintended to be exhaustive or limiting to the precise form disclosed.Modifications or variations are possible in light of the aboveteachings. The one or more examples were chosen and described in orderto illustrate principles and practical application to thereby enable oneof ordinary skill in the art to utilize the various examples and withvarious modifications as are suited to the particular use contemplated.It is intended that the claims submitted herewith define the overallscope.

What is claimed is:
 1. A method for controlling a surgical instrument,the method comprising: processing first data received from a firstsensor of the surgical instrument, at a signal processing microprocessorlocal to the first sensor, into information usable by the surgicalinstrument; and transmitting the information from the signal processingmicroprocessor to a controller of the surgical instrument.
 2. The methodof claim 1, further comprising controlling the surgical instrument basedon the information from the signal processing microprocessor.
 3. Themethod of claim 2, wherein controlling, by the controller, the surgicalinstrument based on the information comprises an operation selected fromthe group consisting of stopping an end-effector, starting theend-effector, and ending a process of the end-effector.
 4. The method ofclaim 1, further comprising: monitoring a current draw on a power linecommunicatively coupled to the signal processing microprocessor local tothe first sensor; and determining an issue with the surgical instrumentbased on the current draw and the first sensor.
 5. The method of claim1, wherein the first sensor and the signal processing microprocessor arepart of a single module.
 6. The method of claim 1, wherein thecontroller is positioned at a handle of the surgical instrument, and thesignal processing microprocessor and the first sensor are located in acomponent separate from the handle.
 7. The method of claim 6, whereinthe surgical instrument comprises a shaft configured to communicativelycouple the signal processing microprocessor and the handle.
 8. Themethod of claim 1, wherein the signal processing microprocessorprocesses the first data received from the first sensor locally togenerate the information to enable the controller to use the processedinformation directly without further processing the processedinformation by the controller.
 9. The method of claim 1, furthercomprising receiving, by the signal processing microprocessor, seconddata from a second sensor.
 10. The method of claim 9, wherein the secondsensor is located at an end-effector.
 11. The method of claim 9, whereinprocessing, by the signal processing microprocessor, the first data intothe information comprises calibrating, by the signal processingmicroprocessor, the first data in response to the second data from thesecond sensor.
 12. The method of claim 1, wherein the surgicalinstrument further comprises a memory in communication with the signalprocessing microprocessor, wherein the memory is configured to storecalculation data that enables the signal processing microprocessor toprocess the first data received from the first sensor.
 13. The method ofclaim 1, wherein the first sensor comprises a magnetic sensor located ata first jaw member of an end-effector, and a second jaw member of theend-effector includes a magnet, wherein the magnetic sensor isconfigured to detect changes in a magnetic field caused by a movement ofthe magnet.
 14. A method for controlling a surgical instrument, themethod comprising: receiving, by a signal processing microprocessorlocal to a first sensor of the surgical instrument, first data from thefirst sensor; receiving, by the signal processing microprocessor, seconddata from a second sensor of the surgical instrument; processing, by thesignal processing microprocessor, the first data received from the firstsensor, into information usable by the surgical instrument; transmittingthe information from the signal processing microprocessor to acontroller of the surgical instrument; and controlling the surgicalinstrument based on the information from the signal processingmicroprocessor, wherein the signal processing microprocessor processesthe first data received from the first sensor locally to generate theinformation to enable the controller to use the processed informationdirectly without further processing the processed information by thecontroller, and wherein processing, by the signal processingmicroprocessor, the first data into the information comprisescalibrating, by the signal processing microprocessor, the first data inresponse to the second data from the second sensor.
 15. The method ofclaim 14, wherein the controller is positioned at a handle of thesurgical instrument, and the signal processing microprocessor and thefirst sensor are located in a component separate from the handle. 16.The method of claim 14, wherein controlling the surgical instrumentbased on the information comprises an operation selected from the groupconsisting of stopping an end-effector, starting the end-effector, andending a process of the end-effector.
 17. The method of claim 14,further comprising: monitoring a current draw on a power linecommunicatively coupled to the signal processing microprocessor local tothe first sensor; and determining an issue with the surgical instrumentbased on the current draw and the first sensor.
 18. The method of claim14, wherein the first sensor and the signal processing microprocessorare part of a single module.
 19. The method of claim 1, wherein thefirst sensor comprises a magnetic sensor located at a first jaw memberof an end-effector, and a second jaw member of the end-effector includesa magnet, wherein the magnetic sensor is configured to detect changes ina magnetic field caused by a movement of the magnet.
 20. Anon-transitory computer-readable medium storing computer readableinstructions, which when executed cause a machine to: receive, by asignal processing microprocessor local to a first sensor of a surgicalinstrument, first data from the first sensor; receive, by the signalprocessing microprocessor, second data from a second sensor of thesurgical instrument; process, by the signal processing microprocessor,the first data received from the first sensor, into information usableby the surgical instrument; transmit the information from the signalprocessing microprocessor to a controller of the surgical instrument;and control the surgical instrument based on the information from thesignal processing microprocessor, wherein the signal processingmicroprocessor processes the first data received from the first sensorlocally to generate the information to enable the controller to use theprocessed information directly without further processing the processedinformation by the controller, and wherein processing, by the signalprocessing microprocessor, the first data into the information comprisescalibrating, by the signal processing microprocessor, the first data inresponse to the second data from the second sensor.